Forged Carbon Revisited: Mould Design & Strength Optimisation

[@SuperfastMatt]

I thought I was done with forged carbon fiber, but this video is excellent, and has inspired me to give it another go. Right after I finish this ham sandwich.

[@highviscosity749]

Let us know the results.

[@frollard]

HAHAHAHAHAHA...came to comments to suggest sfm might need to play with this again...did not disappoint.

[@Hix-Design]

Lose the bread and ham, the mechanical properties are a bit shit 😂

[@victordinev5229]

I still can smell that episode 😂

[@simblorr]

damn it I came here to make a ham sandwich reference 10 hours too late.

[@justinschnepf]

Absolutely loved the camera trickery when you showed the 3d printer running while talking. Fastest 3d printer in the world!

[@tomhollins5303]

I was thinking the same thing. Someone has been polishing their video editing skills.

[@sovietmaize8277]

@@tomhollins5303 It's really easy though, you just talk reaaaally slowly and speed up the video

[@bonovoxel7527]

YESSS I came for this! :D I started 3D printing thanks to them and I loved to see that. It took me a while to understand he was bamboozling us, one year ago i wouldn't have noticed anything!

[@sillyguy5603]

@@sovietmaize8277 Today's Job: Speak for 8 hours

[@justotalkalottashit8392]

almost sold me an ultimaker there for a second.

[@markbrown9765]

This is, by far, the best company advertising I've ever seen on KZbin. Someday I hope to have our house and shop done so I can get this a try (I've done a lot of fiberglass work in the past). But, until then I still watch all your videos. These are awesome content.

[@easycompositestv]

Thank you very much. We wish you all the best getting your house and shop sorted and we'll be happy to supply you and hear about your projects when you get going.

[@albanthomas6646]

I’m a student trying to make a fully carbon fibre rc airplane for a scholarship project. This companies infinite knowledge on carbon fibre has helped me beyond anything else on the internet. Thank you for sharing your superior insights.

[@easycompositestv]

Glad to hear that we've been able to help you out and provide some insight. Best of luck with your project.

[@Robin-my2gz]

Best composites content on youtube!

[@easycompositestv]

Thanks Robin, appreciate your support.

[@Jpifr]

I see an easy composite video : I like the video first then I enjoy.

[@timvangool291]

I saw it when i opened YT and a smile came on my face haha

[@jeremyplatt]

Hahaha me too!

[@Biscotti.]

The stop motion knolling with sound effects at 9:24 is incredibly satisfying.

[@easycompositestv]

Thanks. I think that was some expertly produced custom sound-scaping (our videographer Ben drumming his fingers on the table!).

[@newagetemplar6100]

I’m usually dumbfounded by some YT channels with high number subscribers, turning out poor quality, practically Usless and non educational content . This channel has got to be in the top 10 and dare I say it TOP channel for technical quality, video production, professionalism and manners to name a few . It puts the mainstream media including the BBC and many others to shame. You do genuinely deserve the views 👍🇬🇧.

[@easycompositestv]

Thanks for the kind words, it's appreciated. We try to improve with every video, not sure that we would quite rival a BBC production yet though!

[@Aaronification100]

This will most likely blow up just like your last forged carbon video! Great job, thank you!

[@easycompositestv]

Thanks. I hope it does 😃. This has actually become a process that we use quite a bit internally at Easy Composites as a great method of producing all manner of small moulded parts. The more it gets seen, the more people can add this process to their 'toolbox'!

[@easycompositestv]

@@IkarimTheCreature Oops, thanks for letting me know - I've updated it; replying to responses too quickly :)

[@IkarimTheCreature]

@@easycompositestv Thank you for continuously bringing innovation to everyday people!

[@easycompositestv]

@@IkarimTheCreature It really is our pleasure.

[@Aaronification100]

@@easycompositestv Exactly! Just like carbon fiber skinning, forged carbon is something that is very much achievable by diy'ers at home, which makes it all the more interesting. Your videos are the reason why i now consider self made carbon fiber parts for my project cars, so thanks again :)

[@CraigLandsberg-lk1ep]

What i love about these videos is you get a useful piece of information in every single sentence, none of this watching for half an hour just to get a single punch line 😅😅 every video makes me smarter! And not easy 😮 lol

[@easycompositestv]

We do spend a fair amount of time consciously trying to find the balance between being informative enough to get the technical knowledge across without it being an information dump. It sounds like we've managed to get it about right on this one so thanks for the feedback. 😃

[@Zorbick]

I use this method to make components for my recumbent trikes. Cranks, suspension arms, etc. I'm glad more people are learning of these techniques from you! Most can't CNC aluminum at home, but with your methods they can get similar stiffness very easily.

[@easycompositestv]

Thanks for the comment, yeah it really is an engineering hack to get high performance parts without a big budget! Glad you've been making good use of it.

[@aerialbugsmasher]

I just took delivery of your cast kit the other day, shipped halfway across the world, inspired by the previous video on the motorcycle engine cover. Can't wait to get started with this.

[@easycompositestv]

That's great to hear, I really hope you get good results with it. And of course, you know where we are if you have any questions or problems 👍

[@Getmcwrapped]

Still blown away these videos are free! Thank you guys so much I made brake levers for my goldwing after the first video and now after this I feel like my excf might need some 🤔

[@easycompositestv]

Thanks for the comment! i'm still riding on the levers made in that last video, I would have normally broken 2 or 3 in that time, maybe just good luck but they have taken a good few drops!

[@GeeCeeAte]

Years ago I was obsessed with making carbon parts. Nowadays I realize I don’t really like doing it, I just enjoy watching this guys videos while he does it haha

[@frznpanda002]

Kit worked great, was a bit disappointed it came chucked in a plain box with no instructions, but knew from the YT Video and my own manufacturing experience what to do. great kit Just wish the presentation was better! Thanks for revisiting this super cool stuff

[@easycompositestv]

Thanks for the feedback and I'm glad the process worked for you. We originally intended the video tutorial to be the instructions (in our experience, this is the way most people prefer to learn) and as such this is always the focus of our attention but it's good feedback to know that you expected, and would have liked, printed instructions too. As it happens, we have started putting together a PDF instruction booklet which will be downloadable from the product page (not that you'll need that now!) but I'll discuss with the team whether adding a printed copy to the box is something we'll choose to do as well.

[@frznpanda002]

Thanks for the reply! Even just a qr code to the youtube video would be great! Not even a full pdf, just a welcome flyer with a qr code! Kit worked great though very happy! Top work guys keep it up thanks

[@EITFM]

one of the best technical instructional channels out there. Informative and well presented. Order coming your way soon. That’s how it’s done folks.

[@easycompositestv]

Thanks for the kind words, it's appreciated.

[@papapetad]

You guys know how to sell your products. You make such excellent, detailed videos that one can only appreciate the effort. I'm on the other side of the planet on a tiny rock but I am yet to find any company that comes remotely close to what you guys are doing and so you're getting some of my money as soon as I am ready to learn and do some composite work on my project car. Cheers.

[@easycompositestv]

Thanks for your kind words, they certainly make it work the time and effort that goes into them. Whilst you guys keep watching and enjoying them, we'll do our best to keep them coming. Feel free to get in touch when the time comes and you're ready to get stuck in.

[@starlitstreet]

Who knew these parts could look so good simply by not putting a ham sandwich in them

[@easycompositestv]

haha yes SuperfastMatt has some unorthodox methods!

[@Jun_E36]

The bread does tend to absorb too much resin

[@jamesonbrowne7658]

The sandwich is structural.

[@lhalloran94]

Your videos are so incredibly well done. I'd never even considered making parts in this method!

[@MrJofArnold]

Curses! Just days after my order you add the long strand to the kit 😆 Great you're listening to feedback and yet again a great video.

[@easycompositestv]

Have you checked whether your kit has the long strand fibre in? - We did start adding it to the kits a bit early in preparation so it's worth checking. If you find you haven't and you have any future orders coming up, let us know and we'll include a pack of the long strand tow free of charge 😃.

[@MrJofArnold]

@@easycompositestv I hope so as I paid extra :D

[@frederikmogensen6887]

You guys.. these videos are so well thought out, jam packed with all the needed information and of the highest quality with the greatest attention to details. Already a customer, and I shall keep recommending easy composites. Keep up the fantastic work

[@easycompositestv]

Thanks for your support and feedback 🙂

[@dustinjefferies8482]

A new Easy Composites video?! LETS GOOOO

[@ДенисКомаров-л4ч]

I have had quite the success in following the last forged cf video, having made myself a set of thru axle rear dropouts for a bike frame. Thank you for encouragement, knowledge and inspiration to take on a new hobby, would never happen if not for this channel.

[@constantinosschinas4503]

These videos are (saying it again and yet again) so well done. They can really freshen up even a very bad day and make viewers, simply, want to go out there and build something.

[@easycompositestv]

Glad you enjoy them.

[@BreakingBarriers2DIY]

This video is so fantastic for someone needing to understand the benefits AND how possible it can be to get started in this. Thanks for such an easy to understand and inspiring look into this. One day I want to build my own parts and this has made that day look closer.

[@easycompositestv]

Glad it was helpful!

[@Sven_Hein]

One thing I'd suggest is to use a deburring tool to remove the flashing. There is way less risk to cut yourself and damage the part with the sharp tip of the knife. They make them in all sorts of shapes and sizes and they are great for 3d prints, too.

[@easycompositestv]

Good suggestion!

[@flyerphil7708]

You may well nave already covered this, but I have filled my 3d printed moulds with resin. It makes them very strong, plus the ability to straighten up slight warping of certain moulds. Fantastic video as always.

[@easycompositestv]

Depends on the shape and size of the moulds, but backfilling can sometimes help.

[@TheSturle]

It's incredibly satisfying to read the comments on your vids. Everyone seems to genuinely positive. Also great advertising for your products. Whenever i see carbon fiber i think of you guys now.

[@easycompositestv]

Thanks for the support. We do like to think we have built up a great community of enthusiasts over the years so it is nice to see.

[@Bruno-cb5gk]

So happy to see this video, I've been planning to try this method for FPV arms for a while, so seeing your approach is super helpful. This channel is an absolute gem!

[@easycompositestv]

Glad you found it useful, thanks for watching !

[@graealex]

Every video gets better than the one before. Thanks for these insights.

[@NickWilliams-sn9ln]

I actually thought I knew all the little tricks with FCF. and once again you gave me a new idea. brilliant!

[@jeroentorfs113]

Me and a buddy used the Easy Composites kit and instructions to make a clutch lever for a husqvarna 701 SM and it worked absolutely perfectly! it was so exciting seeing the part come out of the mold looking almost perfect !

[@easycompositestv]

Nice one, glad to hear you had a successful moulding!

[@VEC7ORlt]

That was one fast printer! Still waiting for that video on moldless construction with infusion over sacrificial 3D print. Also do a video on fasteners suitable for composite work and embedding metal parts into composites. Another problem I saw with anyone making videos on composites - almost nobody makes structural parts, its all hoods, covers, shells and the like, glad to see something different here.

[@easycompositestv]

I know! It'd be great if they really were that fast though, right? Thanks for the votes/suggestions, they're all topics we do plan to cover.

[@DingDongDrift]

@@easycompositestv the bambulab printers are almost that fast, you guys really need to upgrade from that ancient ultimaker

[@gunsmoke132]

​@@DingDongDrift They're not that fast LMFAO

[@DingDongDrift]

@@gunsmoke132 i know it's not as fast as this clip, but still 4x faster than an ultimaker

[@robertopaolucci881]

Nobody makes structural parts because it's almost impossible to do on your garage😂😂 in Lamborghini we made the revuelto monocoque tub in forged, and it takes almost 8 years to develope, imagine in a normal garage without the right equipment😅.

[@chrismanley5656]

Paul from Easy Composites, the hero we need!

[@frikkied2638]

This channel is a gift. We don’t deserve it 🙃❤

[@knoj]

The best of KZbin. Seriously.

[@easycompositestv]

Thanks, glad you appreciate it!

[@tymoteuszkazubski2755]

You could improve strength by putting the long strands near top and bottom surfaces. In the middle they do little for bending loads.

[@LearnEverythingAboutDesign]

Wonderful video! Will get my forged kit on the way ASAP. I have had a lot of requests from people asking to show mold creation and I always send them to your channel. So clear and concise!

[@easycompositestv]

Thanks for the feedback, glad to hear that you find the chanel to be a useful teaching tool.

[@EvelcyclopS]

Your videos are fantastic. Basically one of the best tutorials and education on KZbin.

[@easycompositestv]

Thanks for the feedback, it's nice to hear they're worth the effort.

[@evildream67]

Moment Paul said Hi was the moment I had to give Like button right away

[@philip3708]

The quality of your content is exceptional 👍. Highly appreciated.

[@easycompositestv]

Thanks for watching and commenting, it's appreciated!

[@williamschultz298]

I love the small editing flourishes put in!

[@curtisfoster540]

Awesome, inspiring video as per usual! The 3D printer shot had me ready to put an axe to my Prusa printers there for a second til I realized some video wizardry was taking place lol!

[@landonf8465]

Steven Spielberg of composites tutorials strikes again!

[@thegps7197]

Great video. Really enjoy your tutorials on composite manufacture.

[@easycompositestv]

That's great, thanks for your feedback 🙂

[@stevesloan6775]

Just when I thought your videos couldn’t get any better, you drop this one! Thank you so much for sharing your amazing knowledge with the world. I’m so looking forward to creating my own forged parts. I think I’ll start with my old school Kent 1600 Xflow Cosworth rocker cover for my mk1 escort. Then I’ll try an inlet manifold for twin DCOE Weber carburettors. Thanks again!!! 🇦🇺🤜🏼🤛🏼😎🍀☮️☮️☮️

[@easycompositestv]

Hi Steve, nice to hear from you as always. Off the top of my head, I'm picturing the rocker cover being relatively large, by 'forged carbon' standards. If you do give it a go, it might be worth starting with something smaller; the forged process is easier and more reliable on small, solid components, although the flywheel cover we made in the first video was probably a bit closer in terms of shape and size. Let us know how you get on.

[@billynomates920]

thank you for another excellent video. especially for the extended cad on your website. you are like the titans of cnc of carbon composite but much cheaper to set up in your garage at home! 😄

[@easycompositestv]

You're very welcome. It's been something we've wanted to share for a while.

[@JC0037]

If you want to improve the strength of the drone arm even more with this method, you could have the long fibers added first and last, and using the chopped ones as a "core". Although it will be not as visually appealing as the chopped fibers. One solution for this is to add a very thin layer of chopped fibers, then half of the long ones, fill the mould with almost the rest of the chopped, and lastly the other half of the long fibers with some chopped ones over it for aesthetics.

[@easycompositestv]

The issue with this being that the long fibres are not able to 'flow' around the cavity and take the form of any surface detail which is present. The short strands on the other hand are far more manipulatable and can pick up this detail with far less risk of producing voids in the surface.

[@yuriy77]

@@easycompositestv i have done this exact way about a month ago, by following your first video on forged carbon. after a few trials with molding, I came up with a 4 piece mold for drone arms almost like yours in this video. What a coincidence! After i saw this - got instant satisfaction that i was on a right track to make a successful mould. But i agree with previous comment - i ran long strands of tow as much as i could everywhere, and short strands around small features and on outside surface finish. it came out great!

[@frankj3378]

Yet another excellent video Paul!

[@easycompositestv]

Thanks for your support.

[@JonMurray]

Superb video as always mate and awesome work on the parts.

[@easycompositestv]

Thanks for the comment Jon!

[@kpark5993]

As always, thanks for the great video!

[@easycompositestv]

Thanks for your feedback 🙂

[@peterwooldridge7285]

Super video...great production as always

[@thisoneguy2849]

Bought the forged carbon and prepreg kit to get to know how carbon fiber parts are made. Well I've made like 3 parts for my motorcycle out of the forged carbon fiber, now looking to replace the TC80 with resin printed molds as i'm already familiar with 3d modelling and I can be lazier lmao. Thanks guys for bringing this knowledge with the kits to the general population :)

[@easycompositestv]

Thanks for watching, glad that you've been having success with the process, for sure printing the moulds is a faster route than casting with TC80, although the TC80 is more durable if you plan to make a batch.

[@thisoneguy2849]

@@easycompositestv Yea that was a concern of mine aswell. The tensile strength compared to the TC80(12-17MPa) is quite a bit weaker compared to the tensile strength of the e.g. Anycubic 2.0 Tough Resin wich is 58MPa). Sadly I couldnt find anything regarding the compressive strength but I will see how that translates into reallife use compared to the TC80. Will be alot cheaper aswell as im still in school scrapping by on pocket money :)

[@thisoneguy2849]

@@easycompositestv If i plan to make more ill probably.... I dont know. Maybe CNC some aluminium or ill see the durability test vs the two materials

[@thisoneguy2849]

@@easycompositestv Yea okay, I had tensile strength and felxural strength / modulus mixed up. Yea the resin is quite a bit lower in the overall strength. Gonna see how that affects the moulds / if its even possible to create reiable moulds

[@kristoffer-robinlotze7273]

This is a great vid! I'm definitely using this method when building suspension parts for my streamliner later this year. 😀

[@brentc9381]

I was just making a guide for forged carbon as my master thesis, I'm thorn between thinking this is bad timing or good timing, some points I make in my guide are reinforced in this video I guess. It will be open source, so when it is done, I'll be uploading it and hope to get some feedback.

[@easycompositestv]

Hi Brent, I'd love to read your thesis and give you some feedback when it's done, drop us an email whenever. Great choice of subject, there's a lot of untapped potential for it.

[@mohdshahedab7232]

Superb video quality!!!

[@bens3641]

great video and great explanation as usual. I will need to design a part to use this process!

[@andrewgaidamaka4418]

Very detailed video manual with a lot of useful information. The best for beginners.

[@easycompositestv]

Thanks for the feedback, glad you found it useful.

[@easycompositestv]

Glad it was helpful!

[@InnovativeEngineering]

Cool transition 9:13 !! Very good prep to do this in a video!

[@AntMan50-hz1hb]

I find this a blessing ! .. . The world is starting to shed the old guard ( 1%) ..... The peoples world is coming ... Companies like this will free us from big tech in many ways . Amazing products

[@dudeguyman77]

love these videos

[@The_m41lman]

Could we imagine for a second... a DIYPerks x easy composites collaboration... I would die a thousand happy deaths...

[@kopparsulfat]

Damn good job as allways. You make crazy fine parts. Love it.

[@johnlocke_1]

Your back!

[@victorkmarshall]

Gosh I love this channel

[@JohnJones-oy3md]

I like to think of 'forged carbon' as the oriented strand board (OSB) of composites. Some things you would never construct with it - but often it's strong enough for the job and really doesn't matter.

[@Niki_Parvanov]

If I ever try my luck with composites, I know who I'm buying from ❤

[@easycompositestv]

Glad to hear it, be sure to get in touch if you need any specific project advice.

[@Bruce-i8u]

love it excited to give it a go on a design i have

[@lionelfournier]

Excellent as always!

[@VincentFPV]

I use this techniqe for some time to make my custom quadcopter frames. :) This is nice detailed tutorial.

[@carbonmk1]

excellent video ! you have saved many hours and hours of frustration and learning curve has certainly been reduced in forging forwards ;)

[@xispaki69]

You got me as soon i saw a mark 5 ,love to learn more about moulding with you in the future, peace ✌️.

[@easycompositestv]

Thanks for watching, be sure to subscribe so you don't miss out on any of our future videos.

[@grasshoppersystem]

Nice edit of the 3d printing!!!

[@easycompositestv]

Yes, Thanks go to our videographer Ben for that!

[@antoniofranklyn5923]

Thank you so much for making this video Paul!!!

[@Hix-Design]

Is there any virtue in offsetting the surfaces slightly more and building up a few layers of primer with an airbrush on order to improve the surface quality of the mould? Back when I worked in F1 we used TB650 and often that was pained post machining to improve the part quality. I can’t see how it wouldn’t help in this application…. I’m keen to get myself one of these kits and have a play. It’s brilliant that these kinds of technologies, coupled with the quality of consumer 3D printers these days, means that Joe Schmoe in his garage can knock out some decent quality carbon parts. The world truly is your lobster these days. Great vid as ever @easycomposites

[@easycompositestv]

Thanks for the comment, if you can find a coating that will bond to the print then absolutely you could improve the finish of the parts by finishing the moulds further, printing with a resin printer could also be a good option for improving the finish.

[@Hix-Design]

@@easycompositestv I have a resin printer so could give that a try, I wasn't sure that resin parts would be up to the job, but thanks for the pointer. Thinking about it, I could resin print patterns and then use something like TC80 to make the moulds from the patterns. Cheers

[@efaracing4000]

Epic stuff as always there is no competition!

[@easycompositestv]

Thanks for taking the time to comment, glad you like it!

[@המכונהשבאופנוע]

Your workshop is amazing!!!!!!!!!!!!!

[@easycompositestv]

Thanks! Yeah I love it in there, we've got some upgrades coming soon too!

[@ioandragulescu6063]

this is so fascinating and it is one of the reasons I would get a 3D printer, especially with the Prusia core one announcement. The only problem I have is ... what exactly should I build ? :)) Going to start making a list and when it's long enough then I'll jump in. Excellent video btw.

[@Edyremoh]

That 3d print timelapse edit at 9:00 is real slick, man.

[@easycompositestv]

All thanks to the work of our videographer 😅

[@DenAvia]

Brilliant engineering skills! Thank you so much for sharing!

[@easycompositestv]

No problem, thanks for watching!

[@Dillbeet]

Your videos are very informative and appreciated! please continue making them

[@easycompositestv]

Thanks Dillbeet, we enjoy making them and intend to keep doing so - we have lots more either under way already or already planned.

[@nikukaveh6609]

professional video

[@feynthefallen]

A bonnet with a layer of short cut carbon fibers on the outside for optics and woven carbon fiber on the inside for strength would look simply out of this world.

[@easycompositestv]

Thanks for the comment, this is certainly something we could look at doing, it's perfectly possible.

[@stevenmohr4588]

Fantastic! Thank you for you amazing how to videos! 👌

[@easycompositestv]

Thanks for watching, Glad you like them!

[@chriswilliams8607]

phantastic content, thank you so much!

[@easycompositestv]

Thanks for watching !

[@NO-background-music-in-videos.]

Been watching your videos and they are great.

[@easycompositestv]

Thanks for watching.

[@dekutree64]

3:44 That's quite a sound effect! I have a feeling whoever edited the video was not wearing headphones with good bass... Or was that a huge vehicle passing by the shop?

[@easycompositestv]

Maybe you've got better headphones! I'm checking it now and can't really hear anything, but we are on an industrial estate and operate a busy warehouse ourselves so a big truck is never out of the question!

[@IngeBall]

The editor obviously (and rightfully so) knows that jungle is massive. 😁

[@jeromemarie4770]

love your videos and your enthousiasm, you look very passionate about your work and that make it entertainig and very interesting. thanks for sharing your knowledge. if one day 'll make the step from fiber glass to carbon it be hanks to you

[@easycompositestv]

Thanks a lot for the feedback and nice comments. If you do make the transition, and we've helped in some way, then that's great to hear.

[@bonovoxel7527]

Interesting to see those layer lines on the part! So you straight mould with the 3D parts after 2 passes of RW spray, and not sand and polish the prints before waxing. So 0.1mm lines height is enough to have so little lock to avoid prints postproduction. It's a lot of time saved! Cool!

[@conorstewart2214]

I think the reason they can get away with it is because most mould parts pull straight off close to perpendicular to the parts surface. If you were using a mould where parts pull off parallel to the surface and in an unfavourable direction for layer lines then the layer lines would likely cause issues.

[@easycompositestv]

You could sand the moulds for a smoother finish but for these parts the spray wax did a good job of reducing the majority of the peaks/troughs. It's also easier to finish the parts in the positive for the majority of the time, rather than try and sand all the little internal details in the mould. As long as you aren't makign a large number of pieces.

[@temyraverdana6421]

Great video and useful tips. Thanks a lot

[@easycompositestv]

Thanks for the feedback, glad you found it useful.

[@bonovoxel7527]

I started 3D printing watching your videos, loved to see how fast can print that Ultimaker!! 🤣🤣🤣

[@dmoskva]

To add some spice into the mix, what about using various gauges of longer fibers, or adding some twists into the fibers before wetting down for internal compressive stress

[@easycompositestv]

As long as you think about the practicality of laying it in the mould, then yes no reason why you couldn't mix it up to get different properties.

[@mwinner101]

Great video. I expected some sort of oven curing but I guess it’s not needed or wouldn’t add any additional benefit?

[@ChucksSEADnDEAD]

Depends entirely on the epoxy used. Some cure at room temperature (but have lower shelf life) while others need high temperature to cure.

[@easycompositestv]

As Chuck said, it depends entirely on the resin. You could post cure these parts to improve mechanical and temperature resistance properties. Given that we used 3D printed moulds doing an 'in mould' post cure to support the parts would be limited to fairly low temperatures.

[@UncleSpool]

It would be very interesting to see a further optimization of the carbon weave and structure, by 3D printing a central skeleton piece that can be strategically designed to allow weaving the strands around it, then placing more carbon on top and compressing it. I think it would allow for repeatable results, with less variables. Just a thought, could be way off.

[@easycompositestv]

For certain applications, more precise orientation of the fibres as that may allow, could be beneficial.

[@nman2563]

When is the "Paul" action figure going on sale?

[@syd4952]

The main complaint I hear about carbon fibre is repetitive stress fractures. You should really do a CF vs FCF vs Aluminum test for strength after many many non-failure stresses. Like flexing it over and over.

[@easycompositestv]

Fatigue tests would certainly be an interesting comparison, although it's not something we specifically have the test facilities for at present.

[@syd4952]

@@easycompositestv I guess you would want something a little more professional looking than a motor with a spinning arm on it. Lol

[@brianmiller1149]

Thank you!!

[@Alfaduk]

An excellent update to the process and understanding. 1 thing that could be addressed in the strength and stiffness tests and comparisons, is comparing a forged carbon components to an equivalent volume cast aluminium component. Looking at the process and potential for things that could be produced this way, creating things that would otherwise be a cast aluminium part, could be really worthwhile. My thinking is for producing custom car parts. Not necessarily for the looks, but for the real world application. An inlet manifold is 1 thing. But how about a bellhousing to create a unique gearbox and engine combination? Where a creative person might come up with a bespoke mount for an older engine, to attach a power steering pump, a more modern alternator or an air conditioner compressor. Or something that incorporates 2 of those components.

[@easycompositestv]

For the comparison with solid aluminium, we've already made that exact video. After we did the original forged carbon video, we followed it up with a video dedicated to mechanical testing, I think that will answer most of your questions on that front: kzbin.info/www/bejne/pJnUcpuPhMl6hMU As for some of the parts you've suggested, forged carbon right be appropriate for some of them but (without seeing the exact parts) I suspect at least some would probably be better made using a more conventional moulding process. This compression moulding 'forged' process works best for smaller, solid parts. If you're not familiar with them already, take a look through our back catalogue of videos where we cover a range of composite moulding techniques, including several that can be undertaken without too much by the way of complicated or expensive equipment.

[@matyasiadam4656]

Amazing video again! Very useful info of how deep to make the cavity it is something i have been struggling whit until now. An other problem i had particularly on small features is air entrapment and fibers not flowing in correctly. it is not a packing problem (usually appears on the piston side), it can be a compression problem but i do not have access to other than hand clamps, so i was thinking i could use vibration to help the process. In your experience could this help or just make things worse?

[@easycompositestv]

Good question and well explained. It's interesting that you've been experiencing air entrapment, and interesting that it's predominantly on the piston side. I can picture how, if it was going to occur, that's where it would happen. Is there any possibility that you're underloading the cavity? Although air pockets could occur (especially in some geometries) the clamping pressure is normally sufficient to overcome them. One possibility (not that we've needed to do this ourselves) might be to introduce a 'vent' hole into the mould design (or just drill one in now) to the area where the air entrapment is occurring. It would need to be very small in diameter to prevent reinforcement from escaping but *might* help. As for vibration, I honestly don't know if that would help or not, it's not something we've tried. If you do give it a go, let us know whether it helps.

[@matyasiadam4656]

@@easycompositestv Thank you for the the tip's. Will try them, and let you know if vibrating works.

[@khawajadotd]

Why did you use the long fibres in the center of the arm? Wouldn't it create a better, stiffer component if we split the long tow and applied it to the top and bottom layers instead?

[@conorstewart2214]

The problem with the long tow is that it can’t conform to shapes very well, so if you used it for the outer surfaces it could end up misshapen or with voids whereas the short fibres are very good for getting into details. You could adjust the ratios and use a lot more long tow where the short tow is only used for a small layer on the surface but then you might end up with issues of the part only being strong in one direction.