Motorsport Composite Fundamentals: Hand Layup
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Hand Layup
03.52
| 00:00 | In this section of the course we're going to get familiar with the core processes commonly used in the construction of composites for motorsports. |
| 00:08 | To be clear, the only process we'll be covering from a practical aspect in this fundamentals course is wet layup or hand lamination, before moving on to cover the more complex processes in another more advanced course. |
| 00:22 | However, we wanted to cover all the processes here to give you some reference for the other topics we discuss as we move forward. |
| 00:29 | For now, we just need to understand the basics. |
| 00:32 | There are some composite construction techniques we won't be discussing, such as the use of a chopper gun, simply because it's not that commonly used in motorsport where high performance is the primary concern. |
| 00:43 | We also won't be covering 3D printing of carbon fibre parts, as you'd imagine this requires its own area of expertise that's covered in our practical 3D printing course. |
| 00:53 | So, let's crack into it with the focus of this course, known as wet layup, hand layup or hand lamination. |
| 01:00 | Generally, speaking, this is the simplest, cheapest method that requires the least investment in tools, and that makes it the most accessible. |
| 01:09 | That's not to say there aren't some special considerations needed in order to get the best results, as well as a lot of different approaches for specific applications. |
| 01:20 | As with most of these processes, it's as complicated as we want to make it. |
| 01:24 | This is an open moulding technique, meaning it takes place in a mould where the backing or top layers are exposed to atmospheric conditions. |
| 01:33 | For complete clarity, the mould, sometimes also called the tool, is a solid structure that forms a cavity featuring the details of the desired part. |
| 01:43 | The pattern or plug on the other hand is essentially a replica of the shape of the object that we're trying to make. |
| 01:49 | We make the mould using the pattern, similar to how we make the part using the mould. |
| 01:54 | Back on topic, the basic idea is that the layers of reinforcement are laid out in the mould, with the resin being applied by hand to wet it out. |
| 02:02 | This is usually done with the use of a brush, roller or a squeegee, and the resin is applied to the mould surface before the first layer is laid out, then between each subsequent layer, and lastly over the final layer. |
| 02:16 | The intention here is to ensure that the reinforcement is completely wet through with resin, and that there are no air pockets trapped in the mould. |
| 02:24 | When reinforcement is layered up like this, we refer to the composite as a laminate, with the aim usually being to combine layers to achieve the required mechanical properties. |
| 02:35 | This is why the process is also often referred to as hand lamination. |
| 02:40 | It's typical to use a squeegee to draw out excess resin after the final layer is applied, with the aim of improving the resin to fibre ratio for a lighter part. |
| 02:50 | For a standard hand lay-up, like we'll be looking at in this course, the part is left to cure in atmospheric conditions at room temperature. |
| 02:58 | Afterwards the part can be removed from the mould, and any final processes, like cutting or trimming of the edges to the required shape or coatings can be applied. |
| 03:08 | Although they can be very good, it's unlikely a hand lay-up will give perfect results. |
| 03:14 | There are almost always some small pin holes and imperfections in the finish. |
| 03:19 | Naturally these are harder to avoid as the part and lay-up become more complex. |
| 03:24 | Before discussing alternative curing methods in the next module, we'll summarise the key points here. |
| 03:30 | Hand lay-ups, wet lay-ups or hand laminations take place in an open mould, where each layer of the reinforcement is laid out and wet through with resin. |
| 03:39 | The specific layers of the reinforcement are used to achieve the desired mechanical and aesthetic properties, forming what's referred to as a laminate composite. |
