3D Printed Moulds To Make Carbon Fiber Epoxy Resin Tubes – How to Tutorial
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Published 2022-03-17
I’ve used my Creality Ender 3S1 to create the moulds. Power PLA was used as these have the characteristics of ABS which are, to my opinion, closer to what I need without having to print with ABS. PETG would be suitable as well, but wasn’t at my disposal while making this video.
Link to video’s mentioned in this tutorial:
Lithophane 3D print: • Charizard Pokemon Card Lithophane Res...
Review Creality Ender 3S1: • Creality Ender 3 S1 - Good or bad?! R...
Once printed, I’ve added some bolts and nuts to have a threaded insert that could be used later on. The bolts were coated with some spraycan mould release to ensure a good release of the bolts later on. The nuts weren’t coated to assure a good bond with the TC80 epoxy that will be poured later on.
In this video I’ve used some VAC Cast aluminium filled epoxy resin from @Easycomposites. They now have changed the name to TC80, now Tool Cast resin (Link below to product). Some of the advantages of using this epoxy filled resin is that it has low shrink, higher temp resistance TG, can be poured in bigger volumes.
1.2 Kg was used here for the two mould halves. Keep in mind that this resin has a higher density than water, while calculating the volume you have to add more resin. More information can be found on following product link: www.easycomposites.co.uk/tool-cast-epoxy-casting-r…
After Casting the resin was left to cure for over 24h before having it’s postcure into the oven. You slowly ramp up the temperature till desired temperatures.
The Silicone intensifier was made using some platinum silicone. A 3D printed mould was used to cast the silicone in. For best results I’ve used spiralize/vase/vaze mode in cura. This way you have a continuous print without seams. Some of the advantages of using an intensifier is that it will expand under heat, creating pressure. It will also leave a good finish on the inside of your part. This means you’ll have controllable thicknesses. An aluminium rod was added to be able to remove the silicone mandrel after the epoxy carbon fiber braided sleeve has cured.
To make the tubes I’ve used a carbon fiber braided sleeve with an average diameter of 40mm (link below to product) I’ve folded the edges on the inside so they have a good finish to start with. You could also cut the carbon fiber strands. Some EL2 (Epoxy laminating resin) was mixed using the fast hardener from Easy Composites. Make Sure to mix well. A small amount is only needed and was applied to the carbon fiber sleeve and a bit to the mould that was pre-coated with some chemical release agent to ensure a good demoulding after cure. The epoxy was applied using a brush.
The Two 3D printed moulds were closed with the carbon fiber braided sleeve and silicone mandrel/intensifier in the 3D printed mouldhalves. That way some pressure is created to create a good surface finish. After the the aluminium rod is inserted using some Vaseline as a lubricant. This aluminium rod will create some more pressure and stability of the Silicone mandrel.
After an oven cure of 6 Hours the 3D printed moulds were removed from the oven and let cooled down. The mould halves were released and the silicone mandrel was removed. Leaving a nice carbon fiber tube. Downside was that when using one layer, some airpockets appeared meaning there was not enough pressure. Two solutions here: increase the diameter of the silicone mandrel/intensifier or add more layers. In this case it was easier to add 2 Layers, creating more wall thickness and thus more pressure. The Results were beter.
In the next tutorial I’ll go through more details on how to finish a carbon fiber part with defects!
Link to to Power PLA from additive heroes: www.3dprinthings.be/materialen/additive-heroes-fil…
Link to carbonfiber braided sleeve: www.easycomposites.co.uk/40mm-carbon-fibre-braided…
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web/mail: www.mat2composites.com/
#3DPrint #Carbonfiber #Mould
All Comments (21)
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Excellent video! I have created a ton of carbon parts from 3d printed moulds and I still learnt a bunch from this - very interesting!!
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Wow your techniques and video tutorials are really amazing in demonstrating these advanced yet achievable techniques. Thank you!
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Thank you for a nicely presented DIY video. I did learn a few things that will help me in the future!
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Awesome video! This technique will come in handy for my next project. Built from scratch carbon fiber bike frame.
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Very ingenious ideas to do this with limited equipment. Thank you.
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Awesome technique. Thanks for sharing it 👍
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eindelijk...ik zie dat je terug video's aan het maken bent...toppie👍
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Wonderfully entertaining video to watch. Not sure why YouTube suggested it but glad they did. Thanks for sharing
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Thank you so much for this video. This is the first time I've seen using a hollow silicone plug to apply pressure during heating. This is the perfect solution for a project I'm working on and I've been trying to figure out a good way to make repeatable results, as I have to make multiples of the same part for the project.
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Some interesting ideas in that. Thanks. I'll upload a new video on a wingfoil build with a 3d printed core soon as well. Printing and carbon fits so well. Keep it up
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This is awesome! And for once, a tutorial that's not just a repeat of easy composites tutorials! Very smart use of silicone, me likey! What are you going to use those tubes for?
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Never saw a best suggestion from YouTube, I watch while I work on my exams! Thank you!
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Very inspiring and informative video! Thanks a lot for sharing this process, very cool low budget hollow parts :) I would suggest to apply a quick vacuum on the hollow part of the silikone, maybe that makes removal easier
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Excellent work, very impressive. You might find Argonaut Cycles interesting. They also use Silicon Mandrels. I like how you have used resin to reinforce the mould.👌
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Great skills... Amazing job... Congrats
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Amazing... Thank you for using professional language too (registration keys, intensifier etc), it's useful to know if you want to get into some discussions about some project with other professionals:)
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Thanks, a great video.
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Awesome. Thank you!
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great video! What is your preferred release agent on the mold halves?
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Interesting method. would there be any benefit in putting some sort of controllable heating element in the Aluminium tube to maybe heat the core more and increase expansion/compression from the inside out?
