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This is a chemical product. Before storage or use you must download and read the accompanying safety and technical datasheets.

Forged Carbon Example Compression Moulds CAD Files2 MB

Specification

General Properties
Gross Weight2.65kg
BrandEasy Composites

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This product is classed as dangerous goods for transport.

It can be shipped to all mainland EU countries, Ireland, Balearic Islands, Corsica, Sicily and Sardinia.

Unfortunately, for the time being we are unable to ship dangerous goods to Cyprus, Malta, the Canary Islands, Ceuta, Melilla, Jan Mayan and Svalbard.

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Forged Carbon Fibre Development Kit

This kit includes all of the materials required to undertake compression moulding of high performance forged carbon fibre components. All that is required is a two-part compression mould made from cast resin, 3D printed or machined metal.

Contains 750g premium quality CT-12 virgin chopped tow carbon fibre, high-performance IN2 epoxy infusion resin, RW4 high-build spray wax and ancillaries.


AVAILABILITY:14 in stock available for immediate shipping


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€69.95ex. VAT
14 in stock available for immediate shipping
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Forged carbon components provide excellent mechanical performance that can rival or better that of metals and allows fully moulded shapes to be produced that would be almost impossible using traditional single-sided composite moulding methods. This development kit has been put together to allow engineers and keen hobbyists to experiment and prototype with this highly effective process.

The kit includes 750g of premium quality CT-12 virgin chopped tow carbon fibre, our high-performance IN2 epoxy infusion resin, RW4 high-build spray wax and ancillaries, all of which work together and will create forged carbon fibre parts with outstanding mechanical properties.

The kit is designed to work in tandem with our forged carbon fibre video tutorial to provide an accessible, reliable and comprehensive introduction to the process of compression moulding solid carbon fibre components.

Typical Uses

This Development kit is ideally suited to anyone looking to explore this highly effective manufacturing process and produce functional forged carbon fibre components. Common applications include light-weighting of assemblies by replacing metal components, development of new lightweight structural elements, production of aftermarket and upgraded automotive components and many more uses where conventional composites may not be appropriate. A notable benefit of this process is that It allows the production of high-strength components using only a conventional FDM 3d printer opening up a range of possibilities in this sector.

Use this kit to:

  • Produce solid forged carbon fibre with excellent mechanical performance.
  • Rapidly prototype mechanical components without specialist machinery.
  • Reduce weight by upgrading from metal components

Quantity

The kit includes 750g of CT12 chopped tow and 1kg of IN2 epoxy infusion resin, which provides enough material to produce of 1kg (or 1.4 litres) of solid carbon components.

The Forged Carbon Fibre Process

Overview

Suitable Moulds

In order to use this kit to produce forged carbon fibre parts, you will require a set of moulds designed with compression moulding in mind. These compression moulds can be made by 3D printing, resin casting or CNC machining, as described in the tutorial. See also our tutorial on resin casting a two-part compression mould.

Mould Preparation

Before laminating, all mould sections should be prepared using multiple applications of RW4 spray release wax (included in kit). Any holes or bolt threads should be sealed or smoothed using filleting wax (also included).

Fibre and Resin Loading

The chopped carbon fibre tow and low viscosity epoxy should be accurately weighed and loaded into the mould. This will appear to mean overloading the mould cavity, which is the reason why the mould needs to be designed with some 'compression space'.

Compression

Once the moulds have been loaded with fibre and resin the two mould halves can then be compressed together, This clamping can be done with either a bench vice, G-clamps, or a press. The compression needs to be done gradually over a period of a several minutes to allow time for the excess resin to escape.

Curing and Finishing

After curing at room temperature for around 24hrs, the part can be demoulded and any flashing or nibs removed using abrasive paper. Parts produced from a 3D printed mould can have their layer lines removed using abrasive paper if required.

Where a high-gloss finish is preferred, components can be finished using a spray applied clear-coat or brush applied XCR coating resin (not included).

Full details of the process can be found on our compression moulding forged carbon fibre project page.

What Results Can I Expect?

Done correctly, this forged carbon fibre moulding process is remarkable reliable, consistent and capable of producing accurate components with excellent mechanical properties and very low void content.

The success of the process will largely depend on the design and accuracy of the compression moulds, accuracy of material measurement and - to some extent - appropriate distribution of the reinforcement, all of which should be within the scope of any engineer or keen hobbyist. The surface finish is mostly influenced by the mould tools; machined, resin cast or resin printed tools will generally offer a finer finish than FDM printed ones where the layer-lines will be transferred into the part. For cosmetic finish parts, some minor fettling or filling can be required.

Kit Contents

PRODUCT VIDEOS(2)

Forged carbon components provide excellent mechanical performance that can rival or better that of metals and allows fully moulded shapes to be produced that would be almost impossible using traditional single-sided composite moulding methods. This development kit has been put together to allow engineers and keen hobbyists to experiment and prototype with this highly effective process.

The kit includes 750g of premium quality CT-12 virgin chopped tow carbon fibre, our high-performance IN2 epoxy infusion resin, RW4 high-build spray wax and ancillaries, all of which work together and will create forged carbon fibre parts with outstanding mechanical properties.

The kit is designed to work in tandem with our forged carbon fibre video tutorial to provide an accessible, reliable and comprehensive introduction to the process of compression moulding solid carbon fibre components.

Typical Uses

This Development kit is ideally suited to anyone looking to explore this highly effective manufacturing process and produce functional forged carbon fibre components. Common applications include light-weighting of assemblies by replacing metal components, development of new lightweight structural elements, production of aftermarket and upgraded automotive components and many more uses where conventional composites may not be appropriate. A notable benefit of this process is that It allows the production of high-strength components using only a conventional FDM 3d printer opening up a range of possibilities in this sector.

Use this kit to:

  • Produce solid forged carbon fibre with excellent mechanical performance.
  • Rapidly prototype mechanical components without specialist machinery.
  • Reduce weight by upgrading from metal components

Quantity

The kit includes 750g of CT12 chopped tow and 1kg of IN2 epoxy infusion resin, which provides enough material to produce of 1kg (or 1.4 litres) of solid carbon components.

The Forged Carbon Fibre Process

Overview

Suitable Moulds

In order to use this kit to produce forged carbon fibre parts, you will require a set of moulds designed with compression moulding in mind. These compression moulds can be made by 3D printing, resin casting or CNC machining, as described in the tutorial. See also our tutorial on resin casting a two-part compression mould.

Mould Preparation

Before laminating, all mould sections should be prepared using multiple applications of RW4 spray release wax (included in kit). Any holes or bolt threads should be sealed or smoothed using filleting wax (also included).

Fibre and Resin Loading

The chopped carbon fibre tow and low viscosity epoxy should be accurately weighed and loaded into the mould. This will appear to mean overloading the mould cavity, which is the reason why the mould needs to be designed with some 'compression space'.

Compression

Once the moulds have been loaded with fibre and resin the two mould halves can then be compressed together, This clamping can be done with either a bench vice, G-clamps, or a press. The compression needs to be done gradually over a period of a several minutes to allow time for the excess resin to escape.

Curing and Finishing

After curing at room temperature for around 24hrs, the part can be demoulded and any flashing or nibs removed using abrasive paper. Parts produced from a 3D printed mould can have their layer lines removed using abrasive paper if required.

Where a high-gloss finish is preferred, components can be finished using a spray applied clear-coat or brush applied XCR coating resin (not included).

Full details of the process can be found on our compression moulding forged carbon fibre project page.

What Results Can I Expect?

Done correctly, this forged carbon fibre moulding process is remarkable reliable, consistent and capable of producing accurate components with excellent mechanical properties and very low void content.

The success of the process will largely depend on the design and accuracy of the compression moulds, accuracy of material measurement and - to some extent - appropriate distribution of the reinforcement, all of which should be within the scope of any engineer or keen hobbyist. The surface finish is mostly influenced by the mould tools; machined, resin cast or resin printed tools will generally offer a finer finish than FDM printed ones where the layer-lines will be transferred into the part. For cosmetic finish parts, some minor fettling or filling can be required.

Kit Contents

Downloads (1)

This is a chemical product. Before storage or use you must download and read the accompanying safety and technical datasheets.

Forged Carbon Example Compression Moulds CAD Files2 MB

Specification

General Properties
Gross Weight2.65kg
BrandEasy Composites
Can’t find the answer you’re looking for?Ask our technical team a question.

There is no clearance. Once fully clamped, the mould halves are designed to be in full contact. As you are clamping the mould, there is still a gap as you wind on the pressure which is where the resin and air escapes from. Once fully clamped together, there will be no excess to squeeze out and hence no need to have any clearance.

It's quite difficult to give specific maximum and minimum dimensions for overall size, and wall thickness of parts because the shape and geometry of a component has a significant bearing on these other parameters, as does the mould strength and clamping compression force. To give some approximate indications we'd suggest that thickness should be at least 1mm and not more than 10mm. Overall component size really does come down to practicalities of the moulds and clamping arrangements but again, as a ballpark, maybe 500mm x 500mm. In terms of what scale of detail can or should be included, there's not really any constraints on this other than the fact that you'll probably need to do some sanding and fettling of the finished components and so any detail smaller than, say, 0.5mm should probably be avoided as it's likely to be rubbed out or softened by the finishing process anyway.

Literally just the filleting wax is used. The light bond to the surface and the small area being filled with wax means you do not get any bleed through past the wax.

The IN2 resin used in this kit, has a HDT of around 80C after an oven post cure. It depends where on the engine the part is located and ideally it would be best to measure the temperature of the existing part when the engine is very hot to ensure it would be suitable.

No, the resin is quite low viscosity which helps avoid air entrapment and also the compression itself helps squeeze out any remaining air and excess resin.

Hi, that's a very good question. We did originally develop the kit using the AT30 SLOW hardener for this same reason but we fairly soon realised that it doesn't take very long to get the resin out of the pot and into the mould, generally you're working on relatively small parts and most of the time is in dabbing, consolidating, prodding, closing, clamping. For all of these operations the resin is already out of the pot and so its cure rate is much slow. The 17 mins 'pot-life' really does refer to the time the resin can sit in the pot, once it's on the mould and wetted into reinforcement, you've got more working time and in our experience, we never had a problem with working time on any of these components. If you're working on particularly large or complex parts and feel you need more working time than the AT30 FAST provides, you could just purchase some AT30 SLOW on its own, which could be used instead or mixed with the FAST to create a 'medium', giving you plenty more working time.

The process of skinning with forged carbon is better suited to the resins in the skinning kit. So this kit would have a lot of materials you won't use. You would be best buying the XCR resin and XCR basecoat separately with the tow to get the materials you need.

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Customer Product Reviews for Forged Carbon Fibre Development Kit

5/5 Average rating
1/5/2022
|
Alen M
|

Saw this video, went to your webshop, ordered everything, and made a quadcopter frame out of forged CF. It turned out great. The most challenging part was the mold design. I recorded the entire process, it's on my channel.

3/4/2022
|
Christian C
|

First time making anything and using easy composite YouTube video and their kit I got great results!

31/3/2022
|
Harley Designs
|

I bought your development kit and have been printing moulds and making parts successfully. Absolutely love this process and your development kit was the perfect package.

27/3/2022
|
Eddie
|

I bought the forged carbon starter kit because I saw your last video. Got my first part done yesterday. It turned out amazing. Thanks for those informative videos. Please keep it up👏🏼

25/3/2022
|
Ramy RC
|

Very interesting results, I did try your forged carbon fibre method the other day and turned out great!

25/3/2022
|
The Engineer
|

I LOVE IT! Great video! I've purchased the forged starter kit and made my first part. I am still really impressed - awesome product! Those tests you ran are great for showing the potential of the process. Is it possible to get those sets of data? I would love to use this method for designing and manufacturing the steering wheel of my teams formula student car.

19/2/2022
|
Sea 3D
|

We are super impressed with the product and the ease of use as well as the result. Just finished our first sample piece and have already had 2 enquires for parts using your product !! Looking forward to future projects using your products!

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Shipping Information

Restrictions

This product is classed as dangerous goods for transport.

It can be shipped to all mainland EU countries, Ireland, Balearic Islands, Corsica, Sicily and Sardinia.

Unfortunately, for the time being we are unable to ship dangerous goods to Cyprus, Malta, the Canary Islands, Ceuta, Melilla, Jan Mayan and Svalbard.

For a full information regarding the shipment of dangerous goods, see our delivery information page.

Package Size

There are no package size restrictions or surcharges for this product.

Delivery Cost

To find the delivery cost of this item to your address, add it to your basket and then use the instant shipping calculator on the basket page.

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