The future of carbon fiber? Affordable for most vehicles ? - Page 7 - Fuel Economy, Hypermiling, EcoModding News and Forum

freebeard · 02-22-2018, 01:35 PM

Lotus apparently have a BFL, just like Aricmoto.

The other opportunity for aluminum is as a metal foam. And the opportunity for carbon fiber is as a spooled CF/PLA filament for 3D printing.

kach22i · 02-22-2018, 02:15 PM

Looks like we have a good list of competing materials started.

I'll add Carbon Foam.

Developed for supersonic aircraft (in-fill core), structural qualities and heat resistant.

CFOAM® Carbon Foam - CFOAM® Carbon Foam

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The intended product use may require adhesives optimized for high and low use temperatures, low thermal expansion, electrical conductivity and other important properties.

freebeard · 02-22-2018, 04:58 PM

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I was fast reading at web, and unless I took the texts wrong, there is today some kinds of sheet fabrics of carbon fiber specially made for non autoclave purposes. .... Maybe the future of carbon fiber is also about create better resins, and not just reasearch for the carbon filaments itself.

https://duckduckgo.com/?q=carbon+fiber+stock+tube+and+sheet

I've been looking for an excuse to post these:

Could you stitch diamond pleats in carbon fiber? Could you form the newer bucket seat from bent plywood?

All Darc · 02-22-2018, 09:39 PM

I did a brief research about fiberglass, and it's sheaper not just in materials (sheets & resin) but it can also be shapped more directly, without need a negative mold made from a smoot positive mold.

https://www.rqriley.com/frp-foam.htm

Is fiberglass lightweight and resistant enough for a solar vehicle similar to Morelli shape, lke Solarworld No.1 ?

I'm also curious about hte silico composite made used in Aptera. Any video or text about how is used, the process for shaping ?

freebeard · 02-22-2018, 11:53 PM

You found Robt. Q. Riley. Look for Big Daddy Roth. He laid fiberglass over plaster of Paris and then had his assistant Dirty Doug hog out the plaster after the fact. Examples are in museums:

https://motorcyclemaniac.wordpress.com/2012/04/20/larry-desmedt-aka-indian-larry/

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Is fiberglass lightweight and resistant enough for a solar vehicle

Yes. Are you asking if it's in the capabilities of the home builder? Perhaps. The materials are cheaper, but absent a female mold the finish work can be a budget buster. One trick is to get an approximate surface and then squeegee out resin filler under a layer of Mylar plastic. After it cures the Mylar peels off. With sufficient filler or sufficient coats you can get a smooth glossy finish.

Piotrsko · 02-23-2018, 09:50 AM

Actually Burt Rutan suggests vacuum bagging using some material that doesn't stick to the resin. The resin conforms to the skin giving smooth shiney. Between layers use a woven cloth for built in "tooth"

All Darc · 02-23-2018, 10:01 AM

What is more expansive, a positive or negative mold ?
Maybe a skilled person could built direct in negative, without need a positive first.

How create transparent parts, like the dome in this photo ?
I bet it need help of some industry, to heat and shape plexiglasshuge sheet pressing it against a mold.

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Originally Posted by Piotrsko

Actually Burt Rutan suggests vacuum bagging using some material that doesn't stick to the resin. The resin conforms to the skin giving smooth shiney. Between layers use a woven cloth for built in "tooth"

redpoint5 · 02-23-2018, 12:22 PM

I suggest never working with the Devil's material; fiberglass. I've made repairs to plastic on my motorcycle with it that sucked and broke, and I've tried twice to make a mold of a kitchen sink and that sucked. Plus it's super expensive.

All Darc · 02-23-2018, 12:52 PM

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Originally Posted by redpoint5

I suggest never working with the Devil's material; fiberglass. I've made repairs to plastic on my motorcycle with it that sucked and broke, and I've tried twice to make a mold of a kitchen sink and that sucked. Plus it's super expensive.

What is less expensive than fiber glass, and still suitable to a DYO project of a vehicle ???

Carbon fiber it's a lot more expensive

freebeard · 02-23-2018, 01:04 PM

I knew an artist that made sculptures by putting a (clay?) sculpture in a bag, filling it with 100s of pounds of resin, and then somehow getting the original out of the egg-shaped block of resin. He died of cancer, it hit fast and hard.

And the glass gets under your skin.

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What is more expansive, a positive or negative mold ?
Maybe a skilled person could built direct in negative, without need a positive first.

It would depend on the shape. What is it you hope to make?

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What is less expensive than fiber glass, and still suitable to a DYO project of a vehicle ???

Polymetal.