Moulding Hollow Carbon Fibre Parts Using a Low-Melt Metal Mandrel

Рет қаралды 505,781

Күн бұрын

Product links ► www.easycomposites.co.uk/lear...
Further information ▼
In this composites training video, we demonstrate how low-melting point metal alloys can be used as sacrificial cores/mandrels when manufacturing hollow composite structures.
The process can be used to produce complex hollow structures, such as tubes or frame components by laminating prepreg carbon fibre around a cast metal mandrel, which is then cured at elevated temperature before the temperature is increased further to melt-out the metal core, leaving the hollow composite structure.
For full details on the products used, as well as a step-by-step breakdown of the process, see the project page on the Easy Composites website:
Full Project Details
UK and World ► www.easycomposites.co.uk/lear...
EU ► www.easycomposites.eu/learnin...
00:00 Introduction
02:23 Making The Pattern
03:05 Setting up Barriers for the Silicone Mould
06:03 Pouring the Silicone Moulds
07:52 Casting the Low-Melt Metal Mandrels
13:37 Laminating the Components
16:52 Curing the Prepreg
19:04 Melting Out the Metal Mandrel/Core
20:15 Finishing Work

Пікірлер: 672

@fightfanian Жыл бұрын

When i say this is the greatest composite fiber channel on any platform, i genuinely mean it. The excruciating details are always covered but in the clearest and most concise way. You help us pleebs genuinely understand what we are hoping to achieve in addition to the step by step process. Dark aero is a worthy near-peer, but you are the man.

@sytran666 Жыл бұрын

what do you build?

@fightfanian Жыл бұрын

@@sytran666 I'm working on a turbo 999cc briggs vanguard and a 1200cc vmax powered crosskart, and my perpetually broken 532ci 385 series bbf 1969 f100. I just try to make parts here and there with aluminum and composites. My channel is directionsnotincluded. I'm not a "KZfaqr" I have just posted a couple videos.

@jmforeman02 Жыл бұрын

@@2000jago It's an opinion. I don't think he's stating an objective fact or that he's trying to. I mean it would be impossible to prove that there aren't aliens out there with better composites video on a platform we don't have access to, but who cares?

@deth3021 11 ай бұрын

@@2000jagoyou don't get the whole opinion thing, do you? Maybe work on the reading comprehension.

@tomsmith3045 Жыл бұрын

In less than 25 minutes, not rushed, you not only did a demo of a pretty complicated fabrication method, you did it in two different ways. I started watching these to see if it might be possible to add carbon fiber to my work with model aircraft, and now I'm certain I can do it. But it's not just your techniques that are good, your video presentations are really first rate. I'm sure it took days if not weeks to put together this video. Thank you and great work!

@easycompositestv Жыл бұрын

Thanks for the feedback Tom, and yes, they take weeks!

@IanJohnstonblog Жыл бұрын

This video could be a master class of how to script, produce, and shoot a technical video. Simply incredible, and a joy to watch. Bravo!

@easycompositestv Жыл бұрын

Thanks Ian, you might or might not) be surprised just how much work goes into them, it’s weeks of work, scripts, shooting, retakes, feedback, self criticism, re-shooting, all with the goal of trying to make the subject as clear as possible without it ever getting boring. It’s more challenging than the composites!

@ShaftmanOld7 11 ай бұрын

@@easycompositestvAnd the end result is strong, clear, and lighthearted. Just like the composites you sell. Great work.🥇

@link18953 9 ай бұрын

@@easycompositestvthose of us who have worked in professional video production (entertainment for me) can appreciate the massive amount of behind the lens effort here

@jetstreamer3 Жыл бұрын

Your video's are so well done and the process so well explained I have found myself looking for excuses to try out these projects.

@easycompositestv Жыл бұрын

Thanks, that's great to hear. I hope you find the excuse you need and have a go!

@markarmstrong2592 Жыл бұрын

I agree totally

@ryelor123 Жыл бұрын

@@easycompositestv/videos Its a very interesting topic and I like the fact that your company provides everything needed. However I would caution your not to try to rely too much on vendor lock-in. For instance, revealing the formula for the metal alloys wouldn't hurt since people are often more loyal to companies that are willing to share some of their recipes and you never know when someone might be able to tweak the recipe and make a better alloy. I know that businesses, for liability reasons, like to buy things off the shelf but all those businesses usually started from a common man indulging in a new hobby. Helping people get into the hobby on a low budget can create future customers very quickly. Maybe someone will invent something very useful while playing around.

@sunil_de6856 Жыл бұрын

Man the quality of these just keep getting higher and higher... That animation was smooth

@aspees Жыл бұрын

The older lost mandrel technique is using regular Styrofoam. Carve/mill the foam blank to your mandrel shape. Layup the fibre/resin in the regular fashion as if it was the permeant foam core. After the epoxy cures, you can use acetone to melt the Styrofoam mandrel.

@easycompositestv Жыл бұрын

Only flaw is the limitation of the styrofoam if you want to use higher temp processes like pre-preg.

@brett9382 Жыл бұрын

I actually did this with fiber glass for a rear speak housing in a 56 Chevy bel air. Ended up just leaving the foam to dampen its sound when tge seat belt hit it. Glad to know this was a real technique

@smoky-phil7694 Жыл бұрын

@@brett9382 If it works its a real technique :P if it doesn't it was also a real technique but not a good one.

@jajsamurai Жыл бұрын

@@easycompositestv I've seen the same thing done with home insulation foam boards. I'm pretty sure they can take high temps as they should be fire resistant. then you melt them out with acetone or paint thinner.

@NoahSpurrier 11 ай бұрын

I used to do this ceramics. Built up the clay around the form and it would burn out in the kiln when fired.

@Ptremp 10 ай бұрын

I have absolutely no plan to do any of this but still watched the entire video. Great video

@jannsander Жыл бұрын

Next time I need composite supply I'll buy from you just because you put in all this effort. These videos are amazing and educational. Thank you!

@toejamr1 10 ай бұрын

No kidding! THIS is how you drum up business.

@craigkilkenny7143 Жыл бұрын

I could watch these videos for hours! In reality, I’ll probably never get round to making any parts like these but I still find it super interesting to know how it’s done. Thanks guys

@ddegn Жыл бұрын

I think all of your videos are great but this one really blew my mind. I really want to try this myself. Thanks for the excellent video.

@easycompositestv Жыл бұрын

Thanks, that's cool to hear. It's been a video we've been meaning to make for a while. It's not the answer to most composites conundrums but for specific challenges it can be a really useful process to understand.

@zblurth855 Жыл бұрын

I have no idea why your channel does pop up once a years in my recommendation but it is always appreciated

@gcr100 Жыл бұрын

I have done very very little composite fabrication in my life but this channel makes me want go deep into it

@davidf2281 10 ай бұрын

Incredible. This is like watching a video from the future, but it's now! What a time to be alive!

@phd-composites Жыл бұрын

Having a company that not only offers excellent product, but stands behind them by providing the most accurate video material and support is a rare luxury. Also, for all of us that moved out of the UK😢 the EU based warehouse is a blessing. Can’t thank you guys enough for all the hard work 👍💪💪

@easycompositestv Жыл бұрын

I really appreciate your kind words, and thanks for supporting our guys in the Netherlands warehouse and making it the success that it is!

@REDGRIFFIN100 8 ай бұрын

I've been watching your videos for a few years, they're exactly why I first started watching YT. To be educated and inspired to make things. Really amazing 👍

@alexisrivera200xable 11 ай бұрын

I don't even work in manufacture but was both engaged until the end and able to follow the explanation with ease. Excellent video.

@asterisbampos5869 Жыл бұрын

Easy composites lowkey is becoming my favourite KZfaq channel !

@easycompositestv Жыл бұрын

Thanks for the comment, we replace hype with information! Plenty more to come!

@MDUD777 Жыл бұрын

After watching this video im just impressed with the details and superior description of everything!

@SteHughes90 Жыл бұрын

The team behind these videos are so good.

@shere_kan8329 Жыл бұрын

It's great to get to enjoy a new video from you ! BTW, these explaining animations at 1:30 are absolutely stunning ! They help a lot to understand

@easycompositestv Жыл бұрын

Thanks for the kind comment, that's my first go at 3D animation so I'm glad you found it helpful, I'm sure we'll be using animation again in future videos!

@dynamixsystems 10 ай бұрын

I'm watching this channel for many years, and you taught me so much. thanks! ♥

@stephenbrickwood1602 Жыл бұрын

Your video demonstrates the time, materials, tools and equiped work space others have to put into making a component if you were paying someone else to make your component. Value for money is not always understood. Excellent work.

@guerrillaradio9953 2 ай бұрын

You always have the best ideas! Freakin wood's metal! Brilliant! Even my 3d printed nylon or PC molds can handle wood's! I only do composites for RC planes, but your channel has singlehandedly upped my hobby level to pro, seriously.

@jasonsimonsen4184 Жыл бұрын

What an absolutely amazing tutorial. Thanks for doing this, as they are extremely informative and make me want to really start doing this for a load of parts.

@link18953 9 ай бұрын

This is THE master-class on how to deliver a technical video. Broadcast quality. The content is just as amazing. Every video unlocks a new world of possibilities for me. Thank you.

@easycompositestv 9 ай бұрын

Glad you enjoy the videos. We make a lot of effort to keep the quality as high as we reasonably can.

@katierscott8771 7 ай бұрын

What I love about mould making is the variety of techniques and options that are out there. Coming from a background of Glass casting I am automatically thinking of using the variety of Wax, moulding plaster and Clay, all of which could have their part in some parts of this type of work.

@imaninerrah3127 10 ай бұрын

I have no idea how this wound up in my feed but it's super cool

@ze_german2921 7 ай бұрын

I have been wanting to see something like this for years trying to figure out how to make complex induction tubes for boosted, engine applications or cold air intakes. Amazing.

@easycompositestv 7 ай бұрын

Glad you liked it! It is an ideal application for this method.

@CheersWarren Жыл бұрын

Fairly complex process but you did make a nice light-wt part. Mack trucks had some complex fiberglass engine intake shapes, long before 3D printing, we made external aluminum molds , wrapped mandrel made of inflatable rubber bladders in the laminate, wet, clamp alum molds around in a press, inflated bladder, allowed room temp cure or headed molds as reqd, and repeat! Not Light wt parts but strong. Now similar is done with blow molded abs! ( not as strong though) Cheers Warren

@LupusMechanicus Жыл бұрын

based

@b.w.oostdam8875 Жыл бұрын

As always a SUPERB Video! Thank you very very much !

@TheNathanCater Жыл бұрын

Great video! It got me thinking about how many of my own projects this method could be used for. Also, 12g is impressively light!

@fastbike9845 Жыл бұрын

That's an awesome process, and an even better explanation of how to go about it. Pure genius. Many thanks.

@easycompositestv Жыл бұрын

I'm glad you enjoyed it, thanks for the kind words!

@robertrobert5188 Жыл бұрын

Once again a very educational, easy to understand tutorial. Much appreciated. Keep up the great work!

@easycompositestv Жыл бұрын

Thanks Robert, appreciate the feedback.

@babcockcopper Жыл бұрын

Absolutely stellar demo. Thank you.

@MH-ce2io Жыл бұрын

Another killer video, one my favorite channels on KZfaq

@MJ-iy4fb Жыл бұрын

I love the work you do. Awesome job!!

@AsbestosMuffins 11 ай бұрын

that's genuinely a great idea

@dangoesfast 10 ай бұрын

Your videos are so informative, thank you. I like making stuff and I think your channel has inspired me to start making composite parts

@talopi Жыл бұрын

Thanks for making this video, I never knew that using an alloy with a low melting temperature as the core for a part was even something that could be done. If I ever wanted to make a prototype of a carbon fiber part, I definitely think that this would be the way to do it

@stevesloan6775 Жыл бұрын

Amazing process! I had no idea you could use those low temp alloy in such a way. Please please please keep these videos coming! Very enjoyable content! 🤜🏼🤛🏼😎🍀

@easycompositestv Жыл бұрын

Thanks Steve, we will! A few in the pipeline already, as you’d expect 😀.

@arekraczka4204 Жыл бұрын

It’s fantastic how You explain whole process. Thank You.

@easycompositestv Жыл бұрын

Thanks for the kind words, we do our best!

@TheJimiTenor 9 ай бұрын

Quality of your work is amazing, loving it! Thank you guys!

@easycompositestv 9 ай бұрын

Thanks for the great feedback - it genuinely makes it all worthwhile and makes us want to keep making the content.

@mykeready3742 11 ай бұрын

Fantastic. Very well executed and explained. 👍🏻👍🏻

@newagetemplar6100 Жыл бұрын

Awsome , I’ve heard of low melt alloys before but never actually had a go due to not being able to find any suitable and knowing the actual process without lots of experimenting . As usual your videos are priceless wealth of knowledge . Cheers 🇬🇧👍

@easycompositestv Жыл бұрын

Thanks very much, appreciate the feedback and now you know where you can get some low-melt alloy from 😉.

@Snoop.Driftera Жыл бұрын

Well. You guys are realy a leaders of composites on the market. Many of the methods you showed before weren't known among the general population, but were known among enthusiasts. But this time you really surprised an enthusiast!! You always provide the best in-depth tech info on this topic.

@easycompositestv Жыл бұрын

Thanks very much, that’s even better to hear that we’re managing to show an enthusiast something new. Hopefully we can do this a few more times, whilst also coming back to the more conventional processes as well.

@Russiaconnect Жыл бұрын

No, is not. You wrong

@Snoop.Driftera Жыл бұрын

@@Russiaconnect wdym

@Russiaconnect Жыл бұрын

I mean, these guys are not leaders, but regular good masters. But the technology that is shown in this video is a soap bubble that does not carry any practical benefit, breakthrough technology or anything else new. This method is only an additional problem for craftsmen and confusion for small workshops. There are proven technologies that are better and simpler than the one invented and shown in this video. It seems that the video was created only for a set of views and because there is nothing more to show.

@Snoop.Driftera Жыл бұрын

@JetMax I did not express my thought correct.. when i say leaders, i mean they are leaders of info sphere among other composite manufacturers. Yes, there are bigger companies, such as Norpol, Scott Bader etc, but they provide just boring data sheets and technical documentation, while Easy Composites provides ideas and technologies that can be utilized with their materials. And they are leaders in that sphere. I learend many things by searching and reading a lot of uncomplete and fragmental tutorials before easy composites popped up, and since then there's no need to search for any tutorials, since EC have them all. And for me it is a big motivation to pay due and try their materials.

@ChuckThree Жыл бұрын

Loved that little editing trick at 11:44 !!!

@easycompositestv Жыл бұрын

Haha, yes, we could do this because we actually shot the pour twice. The first time we just had the silicone mould but the weight of the metal splayed the mould and it leaked out, so the second time we braced the mould with the plates, but this meant we had the ‘clear’ take that we could use as an overlay.

@CNCAddict Жыл бұрын

These videos are incredible, thanks for making them!!!

@easycompositestv Жыл бұрын

Thanks CNCAddict, it's a pleasure making the videos is the best part of my job, thanks for watching!

@timpickering1516 Жыл бұрын

As always, an amazing video. Thanks easy composites

@schpiedie Жыл бұрын

Thank you for showing this. Fantastic work!

@streetsweeper2942 Жыл бұрын

"Hi, Paul here from Easy Composites.." Me, Smashing the Like Button!!!

@SONO4B11T Жыл бұрын

So that's how they make swingarms!! Wow, what a playlist you guys have created👏👏 At this point, I'm just going to school to learn the proper calculations as to not hurt myself.

@jimurrata6785 Жыл бұрын

Reminds me of the late 1970's when Gossamer Albatross made the first human powered flight across the channel. In that case a 30m tubular aluminium mandrel was laid up and wrapped in shrink tape. Hot oil was pumped through to cure the composite and then acid dissolved out the tube.

@LeicaCat Жыл бұрын

Adding a comment to help the algorithm and also encourage you to put out more excellent videos. Thank you.

@easycompositestv Жыл бұрын

Haha, thanks Karl; good to feed the algorithm!

@jensonhartmann3630 Жыл бұрын

Never thought I'd see CF take a dump before lol

@carlnewtonfishing6045 Жыл бұрын

What a great video. Thanks for taking the time to make them. So interesting.

@easycompositestv Жыл бұрын

Thanks, glad you enjoyed it 😀

@juanx7492 Жыл бұрын

Muchas gracias por seguir compartiendo este tipo de contenido tan interesante!

@jeanfrancoispoivre4438 Жыл бұрын

C'est incroyable comme vidéo !! merci de partager avec nous 😊

@easycompositestv Жыл бұрын

De rien Jean François, je suis ravi que cela vous ait plu.

@Jacobwlane Жыл бұрын

I emailed you guys a few weeks ago discussing upper control arms being made from CF and had a very interesting conversation!! Very cool coincidence to see this pop up! Thanks for all the content :)

@easycompositestv Жыл бұрын

You’re welcome Jakub, that’s for getting in touch with us and all the best for your project 👍.

@temyraverdana6421 Жыл бұрын

It's an amazing useful video. Thanks a lot

@MaX271 Жыл бұрын

Great tutorial, like the other ones on this channel! Making a CF front splitter for my car seems doable by myself now👍

@slimanus8m Жыл бұрын

1:24 Dann such a high quality video, a step up from an already amazing quality

@bodhescheerer1380 Жыл бұрын

Super cool. You really need to open a US warehouse. The competition is almost non existent . Your prices, selection, and obviously tutorials are in a separate league. I think you’d clean up.

@easycompositestv Жыл бұрын

Thanks for the comment, opening a warehouse in the US is something that we'd love to do, so maybe one day soon! In the meantime our shipping to the US is super fast and isn't too expensive for larger orders!

@F0XD1E Жыл бұрын

These videos make me really wish I had a project that would necessitate composites.

@star_scream9349 10 ай бұрын

Very informative channel. Subscribed!

@ArifKamaruzaman Жыл бұрын

Amazing content as always.

@garagenaffe 10 ай бұрын

Please do more videos. I love to watch them :)

@bestwskier Жыл бұрын

Awesome video as usual!!!

@thewelshdragon1567 Жыл бұрын

As someone how works on an FS car making wishbones like this is incredibly tempting

@annakquinn7084 Жыл бұрын

The Composite GOATS!

@57moto59 10 ай бұрын

That's awesome!!! Now I NEED to make something, but I don't know what yet...

@leelipinski4667 Жыл бұрын

So well explained. Although you made that look so easy, i know from dabling in CF a few years ago it really isn't. Excellent job. 👌

@rodfeher Жыл бұрын

great video and great results

@nicholasdugdale 6 ай бұрын

Excellent videos. This style of manufacturing is still very prevalent in todays industries. I will be attempting this next year.

@CrinosAD Жыл бұрын

Thank you for an excellent tutorial (and commercial) :) The more I watch on this channel, the more I want to make all body panels on my truck out of carbon fibre ...

@ipoopmuffins 8 ай бұрын

this is awesome, man i love carbon fiber

@mohamednassif3714 Жыл бұрын

great work man ❤

@Alan_Hans__ Жыл бұрын

VERY nice. I started watching and subbed to the channel because of my love of recumbent trikes and hoping to 1 day build 1. The melt out metal core almost seems like it should be the holy grail for a lot of bike/trike frame builds. You could easily use a silicone plug whose size would slip out in order to reduce the amount of metal to get inserted.

@easycompositestv Жыл бұрын

Thanks for the comment Alan, I hope to do a velomobile build in the channel one day, I'm sure this method will come in handy for a lot of the parts!

@CatchiestWorm12 Жыл бұрын

Top G Paul back at it again

@mgolabek89 9 ай бұрын

fantastic job!

@JonMurray Жыл бұрын

So cool man. I want to make everything I own into carbon fibre versions haha!

@moriarteaa4692 Жыл бұрын

Freaking exceptional Video editing

@mwsiviero Жыл бұрын

Very cool video as always

@georgef1176 Жыл бұрын

Great stuff! I love your products

@easycompositestv Жыл бұрын

Thanks George, appreciate it.

@tonistaru Жыл бұрын

This is amazing !

@mikegLXIVMM Жыл бұрын

Other low melting alloys: Wood's metal, also known as Lipowitz's alloy or by the commercial names Cerrobend, Bendalloy, Pewtalloy and MCP 158. Also Rose's metal, Field's metal Cerrolow 117, Cerrolow 136 and Cerrosafe.

@g45h96 9 ай бұрын

If I had to guess, the alloy is effectively a type of solder. Especially because I'd imagine the alloy needs to be eutectic to avoid deformation under pressure during the initial cure. And the usually low shrinkage of eutectic alloys is a plus. If this is the case, some neat things can be done, speaking from some experience doing stained glass. You can use the lead free alloy to make the initial madrels and components, and then use the lower melting point alloy with a soldering iron to correct surface mistakes and join parts. We used lower lead solders (higher melting points) to fill large gaps, and surfaced them with the regular 60-40 because it wouldn't melt the 63-37, allowing it to sit on top.

@bigg8925 3 ай бұрын

Enjoy watching your videos. Very easy to follow. Would you be able to include in a video of how to mold in an air fitting in the sidewall of the tubing that will be able to withstand 3-400 PSI

@jajsamurai Жыл бұрын

I've seen this same process used with house insulation foam instead of metal. you form the foam in the shape you want, wax it, create your carbon fiber shell, and then melt the foam using some kind of acetone or solvent. pink insulation foam boards are easily available at your local home depot or lowes.

@remkojerphanion4686 Жыл бұрын

Ең жақсы KZfaq

Moulding Hollow Carbon Fibre Parts Using a Low-Melt Metal Mandrel

Пікірлер: 672