Carbon Fiber - 5 things you (probably) didn’t know
Learn how to make your own high-quality carbon fiber parts: darkaero.com/courses
Before we started building the DarkAero 1, we had to learn a lot about carbon fiber. I want to share with you some important information about this material that will give you a better understanding of it, especially if you want to engineer a part made from carbon fiber.
This video covers 5 important things you need to know about carbon fiber.
1) Not all carbon fiber is created equal
- Carbon fiber is made up of small filaments. There are different "types" of filaments of different degrees of strength and stiffness. Additionally, there are different grades of cloth which determine the number of defects in your cloth weave. It’s important to understand what “type” and grade is right for your project.
2) Resin is the unsung hero
- It's easy to focus on the carbon fiber alone. However, you need to pay equal attention to the resin used. The resin allows carbon fiber parts to hold their shape and transfer load from one fiber to the next.
3) Carbon fiber is coated with a secret sauce
- Carbon fiber manufacturers will add a coupling agent (aka "sizing" or "finish") to filaments. This coating helps the resin bind to the carbon fiber. Without the coupling agent or proper coupling agent, the strength of your parts can be reduced.
4) Process drives properties
- The process (wet layup, prepreg, infusion, etc.) you select will ultimately partially determine the properties of your part. Process drives fiber to resin ratio and part defects. Understand which process makes most sense for the goals of your carbon fiber part(s).
5) Test or be tested
- Because there are so many variables that go into carbon fiber, there aren’t good sources of published material properties available to use for design. This means you need to perform testing to verify your parts meet the desired requirements.
Intro - 00:00
Not All Carbon Fiber Is Created Equal - 00:37
Resin is the Unsung Hero - 03:10
Carbon Fiber is Coated with a Secret Sauce - 05:15
Process Determines Properties - 06:24
Test or be Tested - 08:10
Outro - 09:43
Read more this subject here:
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DarkAero Composites Manufacturing Overview
www.darkaero.com/knowledge/co...
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What are other interesting facts you have learned about carbon fiber? What aspects of carbon fiber would you like to learn more about?
I would be curious to see a detailed "how to" for infusion molding, drawing on what you outlined in this video.
What is the weight ratio of the carbon fiber to the resin for a finished part?
@@chicosajovic7680 roughly 70% carbon to 30% resin by weight. These numbers vary by +/-2% based on the specific part, weave type, and fiber orientation in the part.
Inserts ,fixings, etc and UV protection.
@@DarkAeroInc That seems a bit on the dry side. Have you ever tested this? I work with prepregs and the data sheets usually say about 60% fiber 40% resin (by weight).
I’ve just found your channel. I can’t believe how incredibly professional and thorough your work is. And I am even more impressed by your generosity in creating these professional videos and sharing your knowledge with the world.
Neil, thank you for the kind words and for checking out the channel! Glad the videos have been helpful!
I am full time in carbon Fiber manufacturing. Gayford Carbon Fiber Strad Violins. This is without a doubt one of the best intro's to carbon fiber videos I have seen. I can tell you have a mastery of the properties. Well done! I will start following your aircraft build as I have a Carbon fiber aircraft. A SkyArrow. PS I see you have two thumbs down, obviously some who think Carbon Fiber is spelled "Carbon Fibre" LOL
I read your post as “gaylord” instead of “gayford” 😂
I mean, it is spelt fibre rest of the world. The most advanced composite and carbon fibre manufacturing facilities and technology are based in Europe.
The United States is the only country where it’s called “called fiber.” The rest of the world writes it as “fibre.” Typical American thinking they’re always right 😂 And this is coming from an American
It’s like the difference between “cell phones” and “mobile phones”. The tech for cell phones was developed by what would become Qualcom in San Diego California USA. Equally, Carbon “fiber” developed for aircraft parts were developed by Douglas Aircraft and Lockheed Martin Aircraft in Southern California USA. Just because these materials and processes were eventually marketed to the World does not mean that their original names should not be respected
Your methodical detailed design approach is admirable and impressive. Shows you have determination and patience required.
THE RESIN YOU USE IS JUST AS IMPORTANT!!!!
Can't wait to see it in person...must...find...cash....tree
Thanks for taking the time to share what you have discovered. I have been dreaming about making my own plane for years but keep finding excuses. Your DarkAreo project is very inspiring. Thank you!
Best short summery so far I watched on yt regarding CFRP. Good job!
THANK YOU for stating what I've learned from years of composites experience - Test, test, and more testing!! The only way to verify results is to mechanically test EVERYTHING. Great overall presentation and thanks for mentioning fiber/resin compatibility as well - a hidden key to composites success or failure. If you've done coupon level testing on any of your laminates, I'd be very interested to know the mechanical properties you've been able to achieve.
Thank you! Testing is key!
Imbok - do you do testing of carbon fiber sub assemblies today? Is that a service you offer? What is the fee?
You & your fellow engineers are amazing! Keep up the great work,we'll be watching. Thanks much for the insight!
Fantastic project. Thanks for taking the time to share this with the world. 🇨🇦
I've been into carbon fiber for about 20 years and this has been a really fascinating video. Learned a lot here and everything was nice and clear. Great job
Very informative, accurate and relevant vid. Thx, from France
Very informative video. Thank you
As always great and easy to understand info, keep it up 👍
Thank you for these information rich videos. Clear and concise. I look forward to learning from many of your other videos. Quality content!--You've earned a new design engineering subscriber!
THANK YOU SO MUCH!!!! A MUST WATCH!!!
Thank you so much! I'm always impressed by your infusions :)
Thank you!
This was very interesting and informative. I've been riding a carbon fiber bike for the last 15 years. Thank you.
Very.good, this is the best series of videos on CF I have found, thanks for doing this!
Great video. Went from super simplification of carbon fiber all the way to the spec sheets.
Great information, well presented!
Extremely detailed and well informed video! I used to be on an aero team myself, all of this is legit. 👍🏼
Very clear presentation. Thank you for sharing what you are learning and doing.
Quality work! I’d love some more testing details. Process, Test conditions etc. Absolutely love your channel!!
This is a nearly perfect introduction to the technical details of carbon fiber parts components creation. Please do write a full book on this.
Outstanding info!
OUTSTANDING PRESENTATION!
Thanks for dipping into the weeds on the process and philosophy of carbon construction.
Awesome! thanks for sharing this
KEEP UP THE GREAT WORK!!!
Excellent presentation, I found it very useful. Thank you.
Thanks for the very insightful video!
Short but informative 👍🏽 thank you very much 🙏🏾
YES! Its like the engineering explained version that focuses just on carbon fiber and how to actually make stuff!
wow you knocked it out of the park on this video. thanks a ton
Great presentation. Thanks!
Very cool. Thanks for sharing your knowledge gents.
A nice survey of carbon fiber composites. A video on how you meet part 23 certification requirements with regard to structural capability would be really informative, and specifically on the role of analysis in the certification. Nice work!
Superb Video with Great Technical information that we have used in our Orthopaedic Laminating Procedures for our Patients, please keep putting them on KZhead so we can get the very best Prosthetic Builds for our Customers.
Perhaps a vid on various layup techniques in terms of the direction you might run the fibers in different scenarios (corners, flat plate surfaces, access holes curved parts), would be cool to see. Great stuff, guys. Subscribed earlier today! My uncle built (professional pilot) planes - Cub J-3, serial #1 1001-B0200, and has seen his work, so I really appreciate what you are doing!
excellent video, well presented with all applicable points covered short and simple.
Great stuff guys... As to other CF related content: I'd love to see the full infusion process for one of the more complex parts, all the technicals i.e. how-to in terms of vacuum specs, resin flow and saturation, baking, finishes/UV sealing or what have you. Alternatively, or rather additionally, I'd really like to see how you guys bond different parts together, for example the bulkheads and the airframe (and maybe how you bond your sandwich panels in the first place)? I'm also curios about the motor mounts or the fuel tank install, basically how you bond CF and metals.
They offer engineering and process consulting services, check out the consulting page on their website.
Love the info guys! 👌
Excellent general Engineering advice!
Thank you for actually mentioning the more important factors vs the marketing nomenclature regurgitation most channels spit out.
Sorry I can't even pay attention to what you're saying, that profile view of DarkAero 1 looks sooooo good at 13 seconds in and I can't get it out of my head
When i saw the profile for the first time, I thought of the original Ford Mustang styling. Not sure if they’re even similar but something about it reminded me of the extremely appealing mustang design
DART Aero > DARK Aero
Well done, content presentation, information provided. Very informative and interesting.
Great info! Thank you!
Great info. Thanks!
Awesome - my composites knowledge is limited to spat repairs on my RV-8, this is another level of information that really demonstrates your high level of expertise. I just wish you guys were in the UK.
Thanks a lot..Great video
Well presented! Thanks.
Very well done.
Fascinating subject and you did a fantastic, great video. Seriously guys, I place this at the top 1% of technical videos on KZhead. THANK YOU!
Dan, thank you for watching and for the kind words on the video! :)
Dan - we should see if @EngineeringExplained would give these guys a guest hosting spot!
Most helpful 10 min. for my individual research about "carbon fibers in automotive" project for my thesis. Although this video is about on aerospace :) It was really detailed. -Thanks from Turkey
I LOVE YOUR CHANNEL. PLEASE CONTINUE TO SHARE YOUR TRUTH.
Thanks for sharing. Tonnes of information on carbon fiber here.
Clear and helpful video for anyone who wants to learn more about carbon fiber. Keep up the good work
Thank you for watching and for the kind words! :)
Very nice video! Presenting the big picture so clearly is not easy.
Excellent video!
Love watching your videos. Great work guys. I know it can change, but when do you hope to start test taxis / flights?
beautiful plane! it is really coming along.
Thank you, it is very useful.
Great info!
What a great video
Great videos. Thanks.
Great teaching. Thx.
Thank you.
Please tell us more about testing range for different type of parts that are made up with carbon fiber,and also want to know about different method of stiffening it with resin. Btw this is really awesome stuff💛
Great video.
Ok, So I did watch your "Galvanic Corrosion episode" but I did not subscribe because I was new to YT. NOW I am watching DarkAero again and Subscribing for sure my friend! I've been researching to build a CF frame for my DIY motion Sim rig (works great, but now gotta lose the weight) Appreciate all your info ! DMAX motion sim channel
Thanks for the free CF education! I wish you great success. That appears to be a real slippery aircraft. Should do well on fuel consumption.
Thank you this was very informative as an aspiring aircraft kit designer. Not that I want a company. This is just for me. None the less, the information and the way you explained it is invaluable.
Thank you for watching! :) Good luck in your kit aircraft designs! It's always exciting to see new designs take flight.
Great intro video!
Thank you, this is amazing information. I just saw a custom carbonfiber lid made for a laptop, and the people saying that carbon fiber is cheap and parts are easily made for a 100 dollars, made my jaw drop, because it's not that easy... not all carbon fiber is equal, this video will help me teach a few people about it.
Fantastic!
Great good video! All basic stuff but cold converted so everyone understands
Nice work on both the plane and the channel. Do you use spray adhesives to tack the dry cloth to 1) the mold, and 2) further layers of cloth, before infusion? If so, have you tested with/without spray adhesive to see whether stiffness is affected or delamination is a concern?
Great video!!! It would be great if you could make a video about the different curing methods
Thank you, absolutely great and informative video. One could only have hoped that OceanGate would have taken an as professional approach.
Thank for your articulate explanation. Every time I look at your project I wonder if there is a turbine that could be fitted up front. Perhaps your next design will have a high bypass turofan. Very exciting, guys. So no go on CF wheels? Bending seems better than shattering.
I'm really enjoying learning about carbon fiber from you. I like the scientific approach, and factual data presented. I'm currently prepping some fiberglass pieces to make molds so I can redo them in carbon fiber. In my case, they are just fairings for a bike, so not actually structural, but more education on the material is always a good thing. Thank you!
Glad you are enjoying the videos! We are happy to share lessons learned. Thank you for watching and good luck on your bike fairings! :)
Unless you need stiffness over everything else, S glass grade fiberglass is a better and less expensive material. It actually has a higher tensile strength to weight ratio over commercial/common grade carbon fiber. It's a tougher material that handles impacts and abrasion better as well. In an airplane, with wings, tale, etc you do need the very high stiffness of carbon fiber, but in many applications you don't really. Also, when you combine S glass with carbonized cellulose nanocrystals in the epoxy, you up the various strengths at low cost and low weight. I say low cost if you make the material at home. Once you have read through the research, making C-CNC's at home is not that hard to do. But don't be like the industry and use things like waste wood and paper--use a material that is already high in crystalline cellulose. (Tip, many cellulose based natural fibers used for fabrics contain a higher percentage of crystalline cellulose than wood etc).
@@justinw1765 I’m not sure what parts you’re thinking of. I’m not an expert enough to know specifically what s grade fiberglass is vs what I was using, maybe it was. But I can tell you without doubt that fiberglass is only potentially lighter when talking about needing to use a certain amount of material. Like, if you absolutely need the part to be 1/4” thick and solid regardless of material, then fiberglass might be lighter. However if the part just needs to be able to withstand X amount of stress, then carbon fiber is stronger and needs less material, thus, it’s way lighter. While using less material, it can be more flexible. For my motorcycle fairings, the carbon is a LOT lighter, and absorbs impacts much better. It all depends on what qualities you’re after and what specs are important for the particular part or product.
If every teacher would be as good and clear as you guys, lerning would be joyfull!!!
I’m looking forward to the future of aviation with great minds like this team getting the resources to make shifts in the aviation future.
Another great video guys. That definitely answered my question about CF weight. I’m taking Material Properties right now, and working on a project to test the properties of CF, aluminum and balsa wood. Tons of nerd fun haha. What’s the lightest part you’ve made?
You guys keep impressing me. Very good video. Man, I can’t wait to see it being flight tested!
Hi. Excellent tutorial. Could you share a bit more about how many final parts (i.e wing, fuselage etc) you are manufacturing in the row. I assume there should be at least three because you need to test couple of them
Great video! I found there is great variability in stiffness among different resins. Resin stiffness effects how securely the carbon fibers are held in place, and that significantly effects the overall strength of the composite. Could you please cover resin stiffness variables in a future video.
Thanks for watching and the comment! Resins is a big topic so it probably is deserving of its own video. Thanks for the suggestion.
I’m new at carbon fibre as well, and we were making a part to split my cowl last week and noticed that the cowl was actually polyurethane, not epoxy and had to find a source for that type of resin. I would be curious to know the difference other than harshness of chemicals in the application process. We did a demo with the leftover resin to make it smoke and saw temps of 300F when adding too much hardener intentionally and the resin essentially burned itself and changed colours over about 15 mins. A discussion on ratios and how it affects strength and the chemical process that takes place when it cures would be fascinating.
Excellent videos ! Content is super !! Sir where do you recommend to buy resin that performs well on high temperature ?
Very interesting!
Thank you
Your build is fascinating to follow and your knowedge and care is admirable. I have a couple of questions about repairability and survivability: I have heard of carbon fibre airframes being written-off after relatively minor damage, as localised repairs are not feasible in a pressure structure or in a dynamic component. A low speed runway overrun in a Premier jet with little obvious damage resulted in a write-off - and a well-publicized bird strike on the wing of a Premier1 jet which looked minor was deemed uneconomic to repair and the entire airframe was written-off. I realise that DA1 is not a pressurized aircraft, but it is fast. How would say, leading-edge or airframe damage from a bird strike be dealt with? Secondly, there's crash survivability. In the motor racing world, it was realised that carbon fibre can shatter on impact, creating dangerously sharp pieces - and designers had to protect occupants from this in the cockpit design.
Hay bro, Good information and I like your Channel very much much educative. I have a question on machining carbon fibre especial drilling what's is the best property for drilling and milling carbon fibre parts??
I would enjoy seeing you expand on the segment "TEST OR BE TESTED". How did you determine the size and shape of the coupons that you tested? And, how did you choose the particular type of test(s) that would provide you with useful data? What was your sample size? (The number of tests of the same material/process) And, for those of us who may not have the test equipment of our own, how would we find and select a test lab who would be suitable for this type of testing? And referring to a previous video, you mentioned that you are producing your own sheets or sandwich materials. How do your materials compared to the materials that you found commercially available?
Great video, practical course about carbon fiber in 10 minutes.
Thanks for watching! :)
Not planning to make anything from carbon fiber, so why did I find your video useful? I sure as hell enjoyed it though, as I have all your videos. I love what you're doing... that baby sure makes my juices run! Liked (of course) & Subscribed (way back). Keep it up thanks.
Thanks John!
Covered all the bases ,well done! I remember a comment by the teacher I had in an advanced composites course. “ If you get it wrong there will be a pissed off pilot” a voice from the back of the class “ But not for long!”...
Oh how I wish that I lived closed by you. I could learn so much from you guys. I design, build and fly radio controlled airplanes as a hobby for over forty years. I recently designed a 60 inches plane that the wooden main spar alone is over a pound. From previous experience I know that I need this size spar. But if I could figure out how to make a carbon fiber spar I can reduce that weight to half. But I learned a lot from your clip. Please keep up the good work, and happy landings!!!!
I have seen people use different size carbon fiber arrow for spars. The arrows come in many different sizes and stiffness.
An important topic I don't see often on composites is best methodologies for bonding of sub assemblies. For instance, for a carbon fiber tub for a super car for instance, its obvious that they are made of several sub-assemblies that are bonded at critical joints. That may be a good topic for a video. Thanks!