Notes Assignement

design and make a 3D mold (~ft2), and produce a fiber composite part in it

What i am going to do

I want to build a miniature version of Boat Hull using composite materials .

What is s Composite Material?

Composite Material Fab Academy

A composite material also called (Composition Material) is a material made from one or more materials with diffrent chemical or physical properties .

Concrete is the most common example of composite material. Composite Material Fab Academy Concrete

Some Other Composite Materials I studied.

Carbon-fiber-reinforced polymer

Fiber Glass(fiber-reinforced plastic)

Paper composite panels

Benifits of Composites

-Non -Corrosive

-Non -Conductive

-Flexible

-Design Flexibility

Mould Design

I am going to design my boat in Rhino , It is very simple first i created shape of cross section and i used “Sweep2” command for making entire boat hull structure from this cross section, I added a screen video of Rhino Designing in the Composite Materials Assignment -Jaseel ,Fablab Trivandrum Video .

Composite Material Fab Academy Rhino

Composite Material Fab Academy Rhino

Download Rhino File

Download STL File For Shobot

Making of Mould

I used Shopbot CNC machine used for creating mould on 18mm Plywood .
I explained opertaions of Shopbot in My Computer Controlled Machining Week . the diffrence is in Computer Controlled Machining Week i used 2D file .dxf file as input because it is profile cutting only and for making this mould i need carving thats why i need to use 3D(.stl) file as input .

Composite Material Fab Academy Rhino Shopbot

Composite Material Fab Academy Rhino Shopbot Shopbot started its opertaion , it taken 15 Minutes for Rough Cut and 30 Minutes for Fine Cut .
Composite Material Fab Academy Rhino Shopbot
Mould Output from Shopbot , The Mould is ready next step is adding composite to this mould.
Composite Material Fab Academy Rhino Shopbot

Materials Used

1)Matrix Material

Matrix Material (2 Part epoxy ARALDITE Multipurpose epoxy resin)

Resin and Hardner in 1:1 ratio.
Composite Material Fab Academy Rhino Shopbot

2)Fibers

Nylon and Jute

I taken 2 layer of Nylon and a layer of Jute in between them .

Composite Material Fab Academy Rhino Shopbot

Process

1)Mould Design(Explained above) 2)Mould Making(Explained above) 3)Preperation of Resin and Composite Materials(Explained above)

4)Creating composite layers

I created 3 layer composite , i sandwiched two nylon layers with jute and we need to wet all fiber layers using Resin Mix(Resin+Hardner 1:1) and do it slowelly and carefully.

5)Vaccum Bagging

After covering with a plastic sheet we need to vaccum bagging using a Vaccum bag and vaccum cleaner .

I forgot to take picture of this process thats why i am adding the picture of my colegue Rashid .

Composite Material Fab Academy Rhino Shopbot

6)De Moulding

Normmaly it takes 24 Hours to set in room temperature but i taken after 12 hours need to remove excessive material using a tremel or blade .

7)Final

This the final product, bot is waiting for water :) .
Composite Material Fab Academy Rhino Shopbot Problem

Process Video

Composite Materials Assignment - Muhammed Jaseel ,Fablab Trivandrum from Jaseel on Vimeo.

Problems Faced and Solutions

Composite Material Fab Academy Rhino Shopbot Problem

After making composite materials i covered my workpiece with a breather cloth and i created some vent holes air passage, unfortunatellly small amount of resin coming from composite to that breather cloth then it sets . thats why some amount of breather cloth sticked in my boat.

Solution

never add excessive amount of resin in especially in top layer .

New Things I Learned

I learned lot of new things in this week , mainly i learnded how to make composite materials for our needsmainly using resin .