Carbon Fiber Aircraft Wing

[@gateway8833]

How do you figure out the layout of the different layers and orientation of all the constituent components of the carbon fiber.

[@cesarmathias9796]

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[@reececameron4936]

@Cesar Mathias instablaster =)

[@cesarmathias9796]

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[@cesarmathias9796]

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[@reececameron4936]

@Cesar Mathias Happy to help xD

[@kyrillkryvenko752]

Good pace, nice, accurate job. Why did you wet the foam at all? I think there is plenty of resin in the skins to do that. Instead, I would recommend less aggressive perforation of the release film, around 30-40mm pitch. You should have breather half-dry ideally. If it gets fully impregnated with the resin, the airpaths are blocked and vacuum does not work that well. Also, just a recommendation... To get stronger vacuum, use a long aluminium perforate tube instead of single port. At least 1m long for such a job. Plus add another port in the farthest corner and use it just for measurement. This will truly indicate how good is the vacuum. Regarding vacuum pump, get yourself a nice little pump from Easy Composites. It provides excellent abs. pressure, is very reliable and does not evaporate oil.

[@sliu2010]

Did you spary paint into the mold before layup?

[@Dur21]

Hi Chris great video. What kind of vacuum pump you using? That's a very big pump.Best Regards

[@TheDisabledGamersChannel]

Any idea what the weight of that part of the wing equals out to ?

[@farkhodkhikmatov4738]

How is everything going? Are you still doing the project

[@davidxu6477]

that is only one surface of wing, how about the other, and how to connect them together with enough strength?

[@g.zoltan]

Well, it is safe to assume that he makes the other side of the wing too, and that he's building at least 2 total wings :) The two sides are glued together. The contact is usually the main spar, also made separately. In the end 3:58 you can see that he left out a part where the main spar will be glued.

[@davidbradley3074]

What type and who thick is your foam core?

[@BharathwajK]

Can this be used for 3D filament

[@VinothKumar-qo7ry]

How you positioned the foams ?

[@Vik-kw4sy]

What are the components epoxy mixtures for gluing foam cores

[@valderja]

So how long does it take to build everything?

[@gearond]

thank you very much for such a cool demonstration. For your sick, however, I would like you to build a autoclave around that wooden tabletop where you brought the temperature up to whatever it is I guess a hundred fifty degrees. You have some potential to have droop in hot weather and you aren't too strong without autoclaving

[@manuelgzl2884]

Can u built wings for a cessna 210?

[@hamlulit]

What about the seam between the top and bottom carbon sheets once you cut out the wings ? It will show and start to separate ?

[@chrischristiansen5260]

Not sure I understand?

[@guintube]

Chris, I like the fact that you set up a metal mold. However, I have heard that molds should be thicker and of similar materials ie glass or graphite, I guess due to thermal reasons? Was this a concern for your project? Making a thicker mold out of the same material is very time consuming and takes a lot of work. I like your idea, but have not seen it done before.

[@chrischristiansen5260]

Yes, you are right. Production molds should be out of similar materials. Mostly this is done because the heat curing is done in the mold. If not heat curing in the mold, not as big of a concern. I'll be post curing after assembly so not a problem for my project.

[@guintube]

There is some heat during the resin kick off, correct? But was this not high enough to worry about? Just wondering. Do you have any more videos of the project? thanks

[@chrischristiansen5260]

Not as much as you'd think. Total layup is pretty thin so it can't really generate any noticeable heat. I held it at about 95-100f during initial cure and will post cure later.

[@guintube]

Thanks for the reply. Show us more videos of your project when you get a chance...

[@gearond]

It depends on whether you autoclave the part on the mold or how much heat builds up from curing. The best results are achieved with a similar material mold you don't have any pulling and pushing between the mold and the part when there's any change in temperature

[@svetoslavvelev8924]

Would you say what epoxy resins you used (brand, type)?

[@ufoengines]

You guys planning in the near future to use hemp in constructing aircraft parts?

[@chrischristiansen5260]

+ufoengines not yet

[@gearond]

Hmm, sounds like a material that would absorb water, have freezing problems.

[@mikej7476]

I remember doing that stuff. It's fun at first. Then it gets old. Then it sucks. Then it gets so old and sucks so bad you never touch it again.

[@Roxas99Yami]

lol ?

[@patrickkraemer8905]

Were the spars and struts carbon fiber too? Did you finish the aircraft?

[@chrischristiansen5260]

Patrick Kraemer Yes the spars are all carbon too. No struts though, as this will be a cantilevered wing. This aircraft is still under construction.

[@patrickkraemer8905]

Are you using carbon fiber and foam composite? Any construction videos? I guess the ribs are carbon fiber too.

[@chrischristiansen5260]

Patrick Kraemer Check out facebook.com/Aerostruk for more info and pics. I'll be doing my best to post more and more as this project progresses.

[@ssoffshore5111]

@@chrischristiansen5260 What ever happened with this project?

[@vladshapovalov6637]

A sad spectacle of unskilled work.

[@gusbisbal9803]

Chris, why didn't you just infuse this? Your prepreg method is no more exact than a well infused panel, and you're not autoclaving it so why not just infuse the whole wing? Is it to reduce in resin to mesh ratio? Because I don't think it will be any different. PS. Checked out your facebook page. Well done sir. This is outstanding engineering on a budget. Professional but using older technology to get the same results.

[@chrischristiansen5260]

+gus bisbal From what I've found, infusing large foam cored panels is not ideal or time saving. You need resin channels in the foam(time consuming to form). Resin flow is not consistent between top and bottom panels. Your results may vary.

[@gusbisbal9803]

Chris Christiansen I guess I hadn't considered the size you are using. There are ways around that by feeding resin in different places and resin channels like you say but if this method is working for you I can see why you would use it. To be honest I was surprised at how easily you handled the infused CF sheet i.e. that it didn't fall off the plastic/peel ply when you turned it upside down. I guess I have never tried that. So this is a hand layed up sheet which is then vacuum bagged to remove excess resin. I think I am going to try this. Thank you for posting the video.

[@poppabear9279]

That's some slow curing epoxy. One thing. Your carbon fiber to resin ratio seems quite high. Are you sure 60/40 is desirable? Also, does your foam core also absorb epoxy? This looks like a strong design. Considering doing this to build my own fully carbon fiber aircraft. Do you also make the wing spars and ribs? I'd love to see those. This is the first time I have found your channel. Wondering if you build the entire plane, or just the wings? I have been working with carbon fiber on a small structural basis for quite some time. This, "Make your own prepreg" type design has me intrigued. Would love to take a look at what else you do. I dream of building a light weight, 2 passenger, fast, high performance single engine aircraft out of complete Carbon fiber construction, with all the safety measures. I would like to see if anyone has a design integrating carbon fiber wing cups, for anti-stall behavior. Hard to find anything like this open source, so I'm stuck doing fluid dynamics modeling. Is this part of a kit build, or are you a sub-contractor building for another manufacturer? Hardest part of making anything out of carbon fiber is making the mold.

[@chrischristiansen5260]

Thanks for the input. This epoxy has an open time of about 3 hours at 60 degrees. Ratio is what good for me. Foam is closed cell and only absorbs epoxy in the "cut" open cells on the face. This plane was designed by me and I am building the entire plane.

[@poppabear9279]

Thank you Chris for the input. Can I ask what model plane you are building? I am tempted to build a version of the Pipistrel Virus SW, but using a 915 Rotax, slightly different cupped wing geometery, and complete overkill structural build of carbon fiber composite. The one negative about Carbon fiber, is that if your airplane is ever hit by lightning while in flight, I think it would cause significant damage to the entire aircraft, possibly killing the occupants or destroying the instruments in microseconds. However, Carbon fiber is conductive.. but it shreds , bad. I saw a carbon fiber helicopter rotor, struck by lightning and it demolished the rotor and tail rotor. The helicopter went down, but luckily there was enough momentum and prop remaining that everyone lived. Carbon fiber would likely divert the lightning through the entire aircraft, but I'm afraid the epoxy and other structure would likely be destroyed beyond capable flight.. only bad side. My only hesitation about using carbon fiber honestly for an airframe, wings and full aircraft structure would be this factor alone. I don't know of any Cirrus or other aircraft struck by lightning yet, or any carbon fiber composite airframes that have been struck. Any information on this ?

[@mikelemon5109]

Looks scary to build one your self in life terms and Financially.

[@shehzadkhan7570]

03:20

[@aldoyosbel1728397263]

Can somebody tell me the real truth about the resin, what is the best one, hardest, I bought one system three, what a sh***t.

[@captainr.s.chapin8930]

i am using one from advanced composters riverside CA TO WRAP ;a 500hp HARLEY DAVIDSON MOTOR in a , BD5 and adding carbon nanotubes in the resin for full stealth on my oven vacuum chamber I've just built this co makes parts for space x rockets and fixed the galvanic corrosive issues and a ejection seat twin HD belt drives

[@merlin4real]

Well made, poorly explained. What kind of foam? How many layers of carbon? What is a "special epoxy mixture"? So many vague descriptions. Wish this had a voice over instead of music. But thanks for attempting to explain.

[@Pfsif]

Build a table to work on and act like a craftsman and get off your knees.

[@chrischristiansen5260]

I just forwarded your comment to a friend of mine who lays tile. To say the least, we had a good laugh.