Making Complex Carbon Fibre Tubes Using a Split-Mould

[@watchere]

Is there a reason to use vac instead of just pressurizing a bladder inside the mould?

[@LestaAZL]

In vac, the atmospheric pressure push the mold together. When bladder tries to open the mold, so you would need stronger mold to hold

[@AndrewMillhouse]

@@LestaAZL I was wondering this same exact thing. Thanks for the logical response.

[@easycompositestv]

Yes, it's exactly as LestaAZL has commented. The moulds you need for a pressurised bladder need to be incredibly strong (usually billet aluminium) in order to resist the deflection of the 'unbalanced' pressurised bladder. Therefore they tend to be very expensive to produce. An internal vacuum bag setup like this exerts equal pressure on the inside and outside of the mould, allowing much lighter, more cost effective composite moulds to be used.

[@keronGR]

Good point. Vacuum + plastic film= waste + money. You can make a thicker mould just by adding 3-4 layers of fiberglass or carbon fiber, hence achieving a stronger mould. I prefer the bladder anyways

[@mikeyg4297]

What pressure would a pipe like that hold

[@gabednconfused]

this is the first time seeing your videos. I was designing composite parts in F1 for over 3 yrs of my 6yr stint and this offers the exact concepts and processes used in high level motorsport. Very nice.

[@easycompositestv]

Thanks for the comment, that’s great to hear. 👍

[@slipknotfan2217]

Can i ask what kinda parts you made and for which team? I'm just a big F1 fan and i'd like to know

[@elissitdesign]

+1 on knowing what team you were on with driver and what parts. Pleassseeee!

[@anthonybryantmedia]

@@slipknotfan2217 He worked for Mercedes AMG F1

[@anthonybryantmedia]

@@elissitdesign Mercedes AMG F1

[@Highoctane06]

As someone who is completely new to all of this I just wanted to say you are by far the best information source I've come across!

[@easycompositestv]

Thanks for the feedback. Nice to hear that we're achieving what we set out to do.

[@Thomas-lq7wr]

You guys have brought my DIY hobbies to a whole new level. Thank you!

[@daltanionwaves]

There's a great deal of DIY composite videos on KZbin that often look like epoxy castings with a little bit of fiber in them... So we really appreciate what you guys are doing at Easy Comp, representing proper structural layup, in concise and useful little tutorials with slick production. Quality 🏆

[@easycompositestv]

Thanks very much. Yes, we try to show a range of ways of doing things. We will, in fact, be returning to some simpler and more entry-level topics over the next few videos but they'll always be showing a process that's used for a good reason, even if that reason is simply to avoid the need for complex tools or equipment. Stay tuned.

[@petr878]

It's great that you have resumed the videos.

[@easycompositestv]

Thanks, yes, we're pleased to be getting back on with them.

[@staffa007]

@@easycompositestv great work! cheers from Italy!

[@joshschneider9766]

Most advanced material. Oldest type of mold, used for many materials and applications. Gotta love it! Thanks so much for sharing!

[@lamontcranston8181]

You guys have the best carbon fiber tutorials. Thank you for all that you do. Can’t wait for the next one!

[@easycompositestv]

Haha, thanks a lot. We'll get cracking then!

[@Stellarffxi]

Your workspace is always so incredibly clean and organized... I would love to have a workspace like that!

[@calebverdught]

Amazing! You guys are the pros in explanations. Very very easy to understand! Thank you.

[@easycompositestv]

Thanks Caleb, I'm glad you found it easy to follow. That's always the challenge with these complex subjects.

[@lukaslukas8119]

You guys deliver great content. So good to hear, youre uploading again! Much appreciated :-)

[@easycompositestv]

Thank you Lukas, we appreciate your comments and support.

[@fastfix.indonesia]

for the long time, finally i found channel like this

[@easycompositestv]

Thanks for the comment, I'm glad you like it.

[@crowellovecraft7289]

@@easycompositestv hello am an amataeur when it comes to metals and non etals and materials, as far as i understand carbon fiber has been used extensively in space. i want to know what combination is best for such purpose and what types can i use to build space habitats ... say in the kuiper belt....thanks in dvance

[@RealNotallGaming]

wow im a CNC lathe\milling machine - programmer\operator this knowledge about carbon fiber is what i need because this is not programmable :) is only with free hands and i love it :)

[@easycompositestv]

Great, glad you enjoyed it.

[@supertedogpriken]

Thank you so much for making this so easy and simple to understand even foran simple mind like me. Some day i am gone make the best looking Supermoto/dirtbike ever thanks to you, your videos, and your products. You (guys) are amazing.

[@easycompositestv]

Thanks very much, I'm really glad this is inspiring you.

[@gregreynolds9708]

Finally! These videos are by far the best on KZbin about composites. Please keep making them!

[@easycompositestv]

Thanks Greg, we'll do our best.

[@mrmcbeardy9268]

Awesome video! Its so inspiring to see skilled professionals like yourself sharing your knowledge with those who want to learn. Keep up the epic work. i wish you good health and prosperity during these strange times.

[@easycompositestv]

Thank you sir, much appreciated. Good health and prosperity to you too. :)

[@mrmcbeardy9268]

@@easycompositestv thank you. Namaste 🙏😊

[@krazykillar4794]

I liked and subscribed and as soon as I've learned enough to be competent I will purchase all my stuff from your website. Well done guys 👍 Thank you !

[@easycompositestv]

Thanks, that's great to hear. We look forward to supplying you and seeing how you get on with your project.

[@omegaelixir]

Why these carbon videos seem more satisfying than satisfying videos in general I don't know.

[@Super.-.]

Because you learn something just by looking and get ideas what you can do with it .

[@macmac2584]

Thank you for your time in making these incredibly informative, educational videos.

[@easycompositestv]

Thank you for watching and commenting Mac Mac, we’ll keep them coming 😀

[@xnadave]

Now that I'm stuck at home, I really don't have an excuse to put off my composites projects. Awesome video - thanks!

[@easycompositestv]

Haha, that's true David.

[@04dram04]

Well if we are about to enter a world wide depression, no is not the time for hobbies

[@stevesloan6775]

I watched this years ago... still worth a watch anytime. Great content!! 🤜🏼🤛🏼😎🍀🍀🍀🇦🇺

[@SuperSpartan831]

No way I just watched a video with you from 2008 and then this one popped up in recommended. That was a wild ride figuring out the long hair....

[@easycompositestv]

That’s just part of a 20 year commitment to composites! 👍

[@2ndNatureHairSolutions]

Wow man. I know im not going to he doing this any time soon due to financial reasons but when i do ill know whose videos to turn to. Superb explanations and very soothing to watch. Subbed.

[@easycompositestv]

Thank you, glad to have you on board :)

[@scuderia747bhp]

All of that work for just one pipe, can’t even begin to imagine what it takes to build a koenigsegg, the entire car is a carbonfiber

[@Dougline_]

And that's why they cost millions of dollars as well.

[@pgtmr2713]

At least they won't rust.

[@readysetnogo]

If you want an idea on the labor involved, check out the youtube channel Street Bandito. One of the guys is making (and is almost finished with) a full carbon body 240z. The guys does some fantastic work and his car looks gorgeous, all done himself.

[@Jandejongjong]

GUNER 400 parts;) But dont worrie you Pay for the extra Carbon time:)

[@thegiovannimauro]

@@readysetnogo I believe their channel is the reason why this video was recommended to me. I'm interested in handcrafted/homemade carbon fiber stuff. I'm glad there's other fans of the Street Bandito out here. They deserve more love for all of the effort they put into their builds especially the carbon z.

[@Tarex_]

Yay new easy composites video! and the right video at the right time i need it since i am working on an induction system

[@easycompositestv]

Haha, great, that's good timing then. We aim to please :)

[@Tarex_]

Please you do indeed, i've started with Fiberglass and Carbon Fiber just recently, but have been watching your videos for years and they showed that it is alot of work but no magic involved, i have quite a few molds already, the whole vacuuming equipment is coming together piece by piece, until then i am using a food vacuum pump with the tubes and the clothes bags, which both release awesomely haha

[@suprarune]

finally,ive been waiting so long for a video like this! as always you guys makes such great tutorials! keep it up

[@easycompositestv]

Thanks very much, we appreciate your comments.

[@Guetzer]

was just about to say this too!

[@JF32304]

So THAT'S how those those bike frames are made. Thank you for the tutorial 🙂

[@easycompositestv]

Check out our bike frame build video if you want to really get into the details of it! Thanks for watching and commenting?

[@YszapHun]

How am I so lucky? Just watched the 3-part mould video series a few hours back, and just an hour ago this gets uploaded! :)

[@leonstewart6979]

you guys are killing it with these videos!!! great job!

[@easycompositestv]

Thanks Leon, stay tuned!

[@RunwayHeading]

I don't know how I even found this video just scrolling through KZbin but that is actually a very cool process

[@easycompositestv]

Haha, thanks Dennis, sometimes entertainment comes from the strangest places!

[@capnthepeafarmer]

This is exactly what I was looking for after that bike frame video! Much clearer! I would love to see some more information on compression molding techniques with pre-preg, similar to how the headstock was made on the bike frame. Good stuff, gents!

[@easycompositestv]

Thanks a lot, I'm glad this made it clearer. Yes, we might well do something quite soon on the compression moulding with silicone. Stay tuned.

[@capnthepeafarmer]

@@easycompositestv Excellent! Keep up the good work!

[@F1BOY2007]

Always wondered how the hell this was done.. Thank you so much guys.. Love your videos

[@easycompositestv]

Our pleasure. Thanks for watching!

[@dz1sfb]

Thank you for great instructional videos. I may not get around to using the process, but having a greater understanding of what is required and can be done opens some doors for down the road.

[@petersolomon3505]

what a super explanation, this is going to help me to better explain the process to my clients, thanks!

[@easycompositestv]

Thanks Peter, glad it was helpful.

[@abrahamfeliciano2550]

how can you only have 154k subscribers :( ???? this is the best , most entertaining and useful how to video i have come across related to carbon fiber. definitely subscribed !!!!!!!

[@easycompositestv]

Hi Abraham, thanks for the comments. Well, what we do is quite niche; no cats on pianos, minecraft or just giving cash away so I guess we get quality subscribers, not quantity :)

[@kurtveldeman9291]

Now they have 371k subscribers. Their videos are pure gold. 🤙🏻

[@neonnerd1364]

After watching this I feel like my car needs a carbon intake tube.

[@JDMKEV]

exactly what i was thinking ahaha

[@sepg5084]

Especially that now you know that you could possibly make it at home. I wonder what kind of oven needs to be used though, and at what temps and duration.

[@shadowxlink8661]

same...

[@miguelmurua96]

Why do I find these so satisfying

[@luissalguero697]

Never stop doing this videos please🙏

[@easycompositestv]

We'll try Luis :)

[@thesighbored]

Great knowledge sharing and explanation behind the concepts used.

[@easycompositestv]

Thank you, glad you liked it.

[@CameronCarter1]

Your videos are excellent.

[@easycompositestv]

Glad you like them!

[@SkypowerwithKarl]

Labor and skill intensive. Now I know why CF parts costs.

[@easycompositestv]

Hi Karl, yes indeed.

[@DieselRamcharger]

meh not really. fiberglass parts are cheap as fuck. Cf is only slightly more expensive to work with. but it looks cool and people are easily fooled. so why not charge out the ass for it? the skills here are very basic. the tools very basic.

[@SkypowerwithKarl]

Diesel Ramcharger Basic skills? Then 99% of the population doesn’t possess basic skills. Lol

[@StuninRub]

@@SkypowerwithKarl Just because you can't do it doesn't mean the rest of the world can't.

[@sepg5084]

@@DieselRamcharger if what you are saying is true then make a carbon fiber part manufacturing business and make a killing. Ezpz right???

[@deadmantwen]

Idk why I'm watching these, I'll probably never make anything, but I find them to be incredibly intriguing.

[@easycompositestv]

Glad you enjoyed :)

[@adaam2890]

this guy keeps us entertained during the Quarantine do give him a huge LIKE

[@easycompositestv]

Haha, thanks a lot :)

[@nitrocomposites]

Brilliant as usual guys

[@easycompositestv]

Thank you! Appreciated.

[@antiman167]

Great video! Could you do a video on mould production using a 3D printer?

[@easycompositestv]

Yes, this is pretty much top of our list. Lots of people requesting 3D printed mould solutions; we'll put something together.

[@craigsolomon8292]

I'm so glad I found u guys

[@christianedelmann6880]

So there's a couple videos on older (~2014 ish) formula 1 turbocharger intercooler tubing and what they where doing was the smooth side of the part was on the inside of the tubing. I think this was to preserve airflow and avoid turbulence losses. I really wanted to know how they actually molded those parts?

[@christianedelmann6880]

Link: kzbin.info/www/bejne/goSXaGRoatmIsM0 The part is around the 13:10 mark

[@awc.sorensen]

on that particular part there appears to be no undercuts on the larger opening but the throat of the intake would have likely been separate part of the negative keyed into the rest of the negative part. The process would be generally the same as creating the first mold for a standard part as seen in Easy Composites "Fibreglass/FRP Split-Mould Making Guide" or "How to Make a Prepreg Carbon Fibre Mould", except instead of having a split on the outer layer you would split the internal buck to easily remove it. For more complicated internal geometry you would have to include draft angles in the internal buck in order to ease removal as seen in "Making a Carbon Fibre Bike Frame" @32:30 with removing the inserts for the pass through on the frame.

[@easycompositestv]

Hi Christian, I'd agree with what Andrew says.The best process for parts that are 'smooth on the inside' would either be a made tool (if the part could be removed from the without becoming stuck) or it could be a male tool in more than one part, i.e. a split male tool, this would be common, or - for really complex shapes like induction shapes with multiple turns, then you could even use a sacrificial core. These wash-out or melt-out cores are a whole complex subject in their own right but in general they are made from a material that can be dissolved with water or melted out (lots to consider in terms of cure temp of the prepreg vs melt temp of the core) which is either cast (into a mould) or CNC machined.

[@DavidG2P]

What an amazing video, very clear and easy to understand that complex process!

[@easycompositestv]

Thanks again David, glad you enjoyed this one too.

[@graham5318]

Excellent video, thank you!

[@easycompositestv]

Thank you Graham :)

[@EVLS10]

That is one sexy end product. Wow.

[@easycompositestv]

Thanks for the comment, glad you enjoyed the end result!

[@Nobody-U-Want-2-Know]

Actually, the inner bag stays pressurized to atmospheric pressure, 14.7 psi.

[@ValuedTeamMember]

EASY COMPOSITES Ltd™ My new "drug of choice"

[@bassmunk]

This just makes me wanna make a sweet custom intake lol

[@hfranke07]

It is a shame, that I cant like the video more than onece..... I luv your things

[@easycompositestv]

Haha, thanks. Well, just make sure you spread the word :) We're very pleased to get each and every like!

[@3door3geez31]

Can we use the same process with vacuum infusion instead of pre-preg ?

[@radihaydos95]

he said you can but its not worth it

[@easycompositestv]

It's really very difficult to make something like this using a resin infusion process. Nothing is impossible but the practicalities of dealing with dry fabric and then handling the infusion consumables, it just makes it too difficult.

[@E9JMX]

@@easycompositestv indeed it is. The resin needs heated and degassed for a start. The material needs an activator and heat, to create a pre-formed shape. And then the resin needs injected with compressed air pushing it in, with vacuum at the other side helping draw the heated resin to every crevice in the pre-form. That's the "vague" theory used by aerospace to make resin infused carbon parts 👍 (I worked on autoclaves in this way)

[@anthonytsi]

@@E9JMX The only things that I find wrong with your reply is #1. The A+B epoxy creates its own heat to cure. #2. You only need vacuum to draw the epoxy into the material. #3. Adding compressed air would add air to the mix. Keep in mind I used to do these processes when making carbon fiber prosthetics. Adding to the fact that we both understand manufacturing, our products might require different processes. Just throwing my two cents in.

[@ryno9732]

Your videos are always top notch 👌 thank you for it

[@easycompositestv]

Thanks, we appreciate you comments and support :)

[@Hyperian]

and this is why carbon fiber parts are so expensive

[@easycompositestv]

That's right I'm afraid!

[@PakleniVuk]

Hyperian if you want to make them lower buy price just use industrial machines and bigger number of employees and you can produce more so price will be lower

[@kolyafreeman5414]

@@PakleniVuk industrial machines = money. More employees = money. More machines + more employees + more money invested does not equal more demand.

[@samyoung8470]

@@kolyafreeman5414 + more production + more supply + more availability - price - time ✌✌✌😅

[@sepg5084]

@@samyoung8470 if it was that simple, we would be swimming in carbon fiber products nowadays. Modern mass manufacturing has existed for more than a century now and carbon fiber mass manufacturing has existed for more than half a century now. Even quality carbon bike frames are still in the $1k+ range.

[@saiyashwanthkandukuri4272]

Great video and yeah it's good to hear that you are back with some interesting projects

[@easycompositestv]

Thank you Saiyashwanth, I'm pleased you find this interesting.

[@richardbrady6908]

Have you used sacrificial mandrels 3D printed, this would give you a “tooled” internal surface,

[@muumarlin1731]

What a great tutorial / demo!

[@arshmahajan7774]

Hi guys...thanks for all the tutorials. Actually i was looking to make carbon fibre wheels ...could you guys make a tutorial for that too if possible? Also do you guys ship to India? I really wanted that chemical release agent

[@easycompositestv]

Hi Arsh, thanks for your comments. I'm not sure we'll make a video specifically about making carbon fibre wheels because it's unlikely that anyone at the learning stage of the their composites is going to take-on making carbon fibre wheels. However, the process would essentially be a combination of what you see in this video and in our bike frame video, with a lot of extra complexity and really critical calculations and knowledge for safety.

[@DieselRamcharger]

aerosol wax

[@andrew19682008]

Excellent video as always! 👍

[@easycompositestv]

Thanks Andrew, appreciate your comments and support.

[@VaporheadATC]

This reminds me of my days working on the B-2 bomber. Days I'd rather forget. lol

[@urgencepc4563]

I'm in love with your channel.

[@DP-nr1hz]

I would like to make a carbon fibre person as my personal companion.

[@shawnhollahan590]

Five Star Tutorials !!!! ... THANK YOU

[@easycompositestv]

Thanks Shawn, glad you liked it.

[@aliakbari437]

now we know how hard can it be, when you want to make a Koenigzegg

[@easycompositestv]

For sure, this is labour intensive work!

[@superfluous9726]

Koenigsegg* but yeah it's stupidly hard. And koenigsegg makes sure all the weaves line up then sand down the outer to a perfect matte finish. So if it takes two hours to make this tube for a normal person, you can look at about four to six for koenigsegg.

[@GoFastJames]

Thanks for the amazing content hope you keep making more videos. Wish there was videos many years ago or ways to learn more about composite molding so on. I remember it was hard to find much out there when it came to working with prepreg and doing mould making. When looked around was lack of anyone showing how to do prepreg was like it was a secret so most you would see was doing wet, other than Mclaren F1 or aircraft and few boats.

[@easycompositestv]

Hi, yes, that was our experience when we started out too. That's why, - as we acquired knowledge, figured processes out, or developed our own methods - we wanted to share them with others.

[@DP-nr1hz]

I can and will make anything and everything from carbon fibre.

[@apollo3679]

Wow, I’ve been wondering how to do this for such a long time. This video is content gold!!

[@easycompositestv]

Thanks a lot, glad you enjoyed it and it helped you to understand the process.

[@vukilegumede48]

this is great! Can you list the steps you use here in writing

[@storhammer]

Why would anybody dislike this? Must be the competition.

[@easycompositestv]

Haha, well, who knows?! Sure it's not everyone's cup-of-tea but you'd think if you clicked on it then it probably would be!?

[@ve7yan]

Life is good.

[@abyss5400]

Bro we’re able to build complex carbon Fiber parts so easy… LIFE IS GOOD.

[@Justinsane1337]

You guys make really interesting and good videos. Keep up the good work. Looking forward to more videos.

[@easycompositestv]

Thanks Justin, we appreciate the support. Keeps us going with them.

[@arcadiagreen150]

cost of carbon fiber pieces: 10%, cost of materials.... 90% PITA tax

[@Stojce_]

these videos are really fun

[@easycompositestv]

Haha, then you think like us!

[@volvo245]

This looks exhausting and expensive.

[@RENO_K]

Exactly why carbon parts are expensive

[@TBAPb228]

Been waiting that video ! Good job ! Super !

[@easycompositestv]

Thanks Denis, we needed to get this one out there (to go with the bike frame and the roll wrapped tube vids!)

[@CarlosSD]

1,000,000 views, ¡congratulations guys!

[@easycompositestv]

Yes, amazing how many people have watched this pretty technical video :)

[@ExploringCabinsandMines]

I do this for a living and that was a superb job !

[@easycompositestv]

Thanks Dave

[@Pertamax7-HD]

nice material

[@ther1kid]

Excellent video. Thank you for going more in-depth from the bike frame video technique.

[@easycompositestv]

You're welcome, I'm pleased if this helps to explain/show it a bit better.

[@truth7416]

Well done guys. I learned and am greatful. Keep them coming.

[@easycompositestv]

Thanks a lot, we'll do our best to keep them coming.

[@goury]

I have no idea why youtube recommended me this one, but I enjoyed all of it. Thanks!

[@easycompositestv]

It knows you better than you know yourself!

[@nancysmith9487]

Really nice job, thank yous for sharing your craft... mountain bike came out really nice... and tubular components nifty ideas

[@easycompositestv]

Thanks Nancy, glad you enjoyed it. Thanks for watching.

[@thidasfernando9698]

this is extremely satisfying.

[@luanderferreiradacruz8577]

Muito Loko !!! O cara que inventou quebrou a cabeça surreal

[@deadwood21plus]

This channel make me want to make hypercar company. Amazing video.

[@easycompositestv]

Thanks a lot; maybe you should go for it!

[@sonramnoldu9671]

I liked very much & subscribed to see more please. wonderfully teaching video. thanks a lot.

[@easycompositestv]

You’re welcome, glad you’re enjoying the content 👍.

[@rogeronslow1498]

This is so labour intensive it will never replace traditional metal methods except for absolutely weight critical applications.

[@easycompositestv]

Well, of course that's right Roger; advanced carbon fibre composites are definitely not a potential rival for mass produced forms where weight is not critical.

[@ryansmithza]

Never is a long time and there are always smart people looking to save a it of it.

[@sp276]

I love watching a Pro creating perfection

[@germail86]

I don't know why I'm watching this. But I enjoyed it.

[@Cbegnaud]

I would love to see a cideo of how you made the mold. Love your vids

[@easycompositestv]

Hi Chris, the split-mould we used in this video is a prepreg carbon fibre tool. The patterns (for the two halves) were CNC machined from epoxy tooling board like in kzbin.info/www/bejne/eYikp6Juea6Nb9U and then the mould halves made from made from XT135 carbon fibre tooling prepreg like in kzbin.info/www/bejne/oWWqlXSrg8-ca8k. There are other solutions for making high temperature moulds, such as a hand layup process using high temperature epoxy tooling gelcoat, resin and paste which you can find out about in this tutorial (on our website) www.easycomposites.co.uk/learning/hand-laminating-a-high-temperature-epoxy-mould

[@АльфредМиннибаев-г8в]

Отличное видео. Спасибо !!! Обязательно подпишусь ...

[@VinothKumar-qo7ry]

Thank you very much. Learned lots of stuff.

[@easycompositestv]

That's great to hear, thank you.

[@MrFaiqueShakil]

Bro. you are very talented...

[@easycompositestv]

Thanks Faique :)

[@SoaringExperience]

6:31 at glider fuselagebuilding we use fishing line which goes in a zick-zack (Z-shape; x-shape) over the mould surface to hold down the wet carbon fibres. When the upper mould have is put onto it, we cut the fishing line. Pull it out and everything inside the mould is sitting right. But instead of vacuum we use 3 bar of pressure with a long balloon.

[@easycompositestv]

Thanks Sebastian, it's really interesting to hear about your process; that sounds clever.

[@SoaringExperience]

@@easycompositestv www.f5b.de/rumpfaufbau_2020.html Almost at the end of the page you can see how modell plane builders doing it with the fishing line.

[@epicon6]

Carbon fibre is a life saver

[@dgpgarage9291]

This is awesome! I’m still trying to do the basics

[@f_2476]

It was an excellent work, thanks for sharing us those valuable info's in details 👍

[@easycompositestv]

You're very welcome, glad you liked it.