Moulding Hollow Carbon Fibre Parts Using a Low-Melt Metal Mandrel
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
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.
what do you build?
@@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 "KZheadr" I have just posted a couple videos.
@@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?
@@2000jagoyou don't get the whole opinion thing, do you? Maybe work on the reading comprehension.
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!
Thanks for the feedback Tom, and yes, they take weeks!
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!
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!
@@easycompositestvAnd the end result is strong, clear, and lighthearted. Just like the composites you sell. Great work.🥇
@@easycompositestvthose of us who have worked in professional video production (entertainment for me) can appreciate the massive amount of behind the lens effort here
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.
Thanks, that's great to hear. I hope you find the excuse you need and have a go!
I agree totally
@@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.
Man the quality of these just keep getting higher and higher... That animation was smooth
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.
Only flaw is the limitation of the styrofoam if you want to use higher temp processes like pre-preg.
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
@@brett9382 If it works its a real technique :P if it doesn't it was also a real technique but not a good one.
@@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.
I used to do this ceramics. Built up the clay around the form and it would burn out in the kiln when fired.
I have absolutely no plan to do any of this but still watched the entire video. Great video
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
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!
No kidding! THIS is how you drum up business.
I have no idea why your channel does pop up once a years in my recommendation but it is always appreciated
Incredible. This is like watching a video from the future, but it's now! What a time to be alive!
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.
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.
"Hi, Paul here from Easy Composites.." Me, Smashing the Like Button!!!
Easy composites lowkey is becoming my favourite KZhead channel !
Thanks for the comment, we replace hype with information! Plenty more to come!
I have done very very little composite fabrication in my life but this channel makes me want go deep into it
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 👍
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 👍💪💪
I really appreciate your kind words, and thanks for supporting our guys in the Netherlands warehouse and making it the success that it is!
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.
I don't even work in manufacture but was both engaged until the end and able to follow the explanation with ease. Excellent video.
The team behind these videos are so good.
I'm watching this channel for many years, and you taught me so much. thanks! ♥
Can't wait for a Formula Student team to try this technique on their suspension.
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.
After watching this video im just impressed with the details and superior description of everything!
I have no idea how this wound up in my feed but it's super cool
Your videos are so informative, thank you. I like making stuff and I think your channel has inspired me to start making composite parts
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.
Glad you enjoy the videos. We make a lot of effort to keep the quality as high as we reasonably can.
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.
Glad you liked it! It is an ideal application for this method.
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.
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.
No, is not. You wrong
@@Russiaconnect wdym
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.
@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.
Absolutely stellar demo. Thank you.
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.
Quality of your work is amazing, loving it! Thank you guys!
Thanks for the great feedback - it genuinely makes it all worthwhile and makes us want to keep making the content.
Excellent videos. This style of manufacturing is still very prevalent in todays industries. I will be attempting this next year.
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.
that's genuinely a great idea
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
Great video! It got me thinking about how many of my own projects this method could be used for. Also, 12g is impressively light!
That's an awesome process, and an even better explanation of how to go about it. Pure genius. Many thanks.
I'm glad you enjoyed it, thanks for the kind words!
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
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!
I love the work you do. Awesome job!!
Once again a very educational, easy to understand tutorial. Much appreciated. Keep up the great work!
Thanks Robert, appreciate the feedback.
Thank you for showing this. Fantastic work!
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.
Very informative channel. Subscribed!
Please do more videos. I love to watch them :)
fantastic job!
It’s fantastic how You explain whole process. Thank You.
Thanks for the kind words, we do our best!
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! 🤜🏼🤛🏼😎🍀
Thanks Steve, we will! A few in the pipeline already, as you’d expect 😀.
I've watched all of these videos in two days. I need more content. 😂
We really appreciate the support, we're currently filming and editing more videos which we hope to upload shortly :)
Fantastic. Very well executed and explained. 👍🏻👍🏻
As always a SUPERB Video! Thank you very very much !
Loved that little editing trick at 11:44 !!!
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.
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
based
Muchas gracias por seguir compartiendo este tipo de contenido tan interesante!
That's awesome!!! Now I NEED to make something, but I don't know what yet...
As always, an amazing video. Thanks easy composites
What a great video. Thanks for taking the time to make them. So interesting.
Thanks, glad you enjoyed it 😀
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 🇬🇧👍
Thanks very much, appreciate the feedback and now you know where you can get some low-melt alloy from 😉.
These videos are incredible, thanks for making them!!!
Thanks CNCAddict, it's a pleasure making the videos is the best part of my job, thanks for watching!
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 ...
Another killer video, one my favorite channels on KZhead
Great tutorial, like the other ones on this channel! Making a CF front splitter for my car seems doable by myself now👍
Awesome video as usual!!!
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.
Amazing content as always.
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.
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!
It's an amazing useful video. Thanks a lot
great video and great results
C'est incroyable comme vidéo !! merci de partager avec nous 😊
De rien Jean François, je suis ravi que cela vous ait plu.
Pretty neat
The Composite GOATS!
Adding a comment to help the algorithm and also encourage you to put out more excellent videos. Thank you.
Haha, thanks Karl; good to feed the algorithm!
1:24 Dann such a high quality video, a step up from an already amazing quality
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 :)
You’re welcome Jakub, that’s for getting in touch with us and all the best for your project 👍.
great work man ❤
This is amazing !
Brilliant!!
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. 👌
These videos make me really wish I had a project that would necessitate composites.
this is awesome, man i love carbon fiber
Freaking exceptional Video editing
Top notch video!
great video
Very cool video as always
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.
Great stuff! I love your products
Thanks George, appreciate it.
So cool man. I want to make everything I own into carbon fibre versions haha!
I have been trying to figure this out for the longest time and not many places on the net had info on melting mandrels. Thanks for showing this process. Could you guys do a short or episode on the proper methods of implementing fasteners and aluminum plates to avoid galvanic corrosion?
Use fiberglass for around the metal fasteners
Or fully 2k epoxy paint the fasteners
Do you really need to worry about it? Galvanic corrosion only occurs in the presence of an electrolyte solution. So unless your parts are going to get wet (and stay wet) with a salt water solution of some kind, it is not a concern. You probably can't walk through a room in your house with out walking past something that has screws running into aluminum - it is not an issue. Don't get sucked into this nonsense.
@@joshua43214 as someone who works in the automotive industry I see galvanic corrosion all the time. If I was making car parts I’d be concerned about this for sure. I guess it depends on his application.
@@KindredAutomotive Yes, cars can be very prone to this if they salt the roads enough to degrade the anodizing. In practice though, it is not a concern for most stuff. Just consider all the aluminum around you; your screen door, your TV, your siding, the signs at your local stores, etc. Galvanic corrosion *requires* an electrolyte
Top G Paul back at it again
Great stuff thanks
Thank you for this video!
You're very welcome, I hope you enjoyed it :)
You rock!🤘🔥
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.
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!
Brilliant.
As someone how works on an FS car making wishbones like this is incredibly tempting
Great work and detalied video!
Thanks for the support :)
Yo Paul thanks some day I hope to be able to ask in more detail about a project that I came up with again I will continue to watch and learn
OK, well, I look forward to it, in the meantime keep learning and planning 👍.
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.
Excellent video...
Thanks for watching and commenting Steven!
This is really cool. 🤔👍