3D Print to Carbon Fiber Development Kit

3D printing is finding its way into all sectors of industry and composites is no exception, this development kit has been put together in response to requests for a convenient kit that can be used to create a carbon fiber part directly from a 3D printed mold.

This kit includes top quality 210g (6.2oz/yd) 2/2 twill 3k carbon fiber fabric, our high performance EL2 Epoxy laminating resin, XCR coating resin, abrasives, compound, and ancillaries all of which work together and will create carbon fiber parts with good mechanical properties and cosmetic finish.

Typical Uses

This Development kit is ideally suited to anyone looking to explore this novel manufacturing process and produce functional one-off or prototype components with a great cosmetic appearance.

Use this kit to:

• Experiment with making carbon fiber products directly from printed molds.
• Rapidly prototype components for customer evaluation prior to traditional tooling.
• Create inexpensive custom one-off and prototype parts quickly).

Dimensions

When unrolled the carbon fiber fabric is 300mm (11.8") wide and 1000mm (39.4") long.

Basic steps:

Starting with a 3D printed mold, we recommend using PETG filament, we have found this to offer an excellent balance of inherent release properties and accuracy, other print materials may well be appropriate, but test should be conducted to ensure compatibility with the process.

The mold can then be coated with PVA release agent. PVA is applied in a single coat either by wiping or brushing an even film over the mold surface.

The part can then be laminated with the carbon fiber and EL2 laminating resin, the kit also includes peel-ply which can be laid onto the back of the laminate to provide a neater finish.

After curing the part can be demolded, the resulting part can now be trimmed and at this stage will have visible layer lines from the 3D printed mold, for purely mechanical applications this may be perfectly acceptable, but the kit does include the XCR coating resin, abrasives, and polishes required to finish the part to a high cosmetic standard.

For further information on the process can be found on the project page Using a 3D Printed Mold to Laminate a Carbon Fiber Part

What results can I expect?

The standard of the end result you can expect will vary greatly depending upon your level of practical skill, effort and perseverance but the materials contained within this kit in combination with the practical advice contained within the printed and video guides are quite capable of producing excellent results.

Kit Contents.

• 0.3sqm (0.36sq yd) 2/2 Twill 3k Carbon Fiber Cloth
• 200g (7oz) EL2 laminating epoxy (inc. AT30 Fast Hardener)
• 500g (19oz) XCR Coating Resin (inc. Hardener)
• 35ml (1.25oz) PVA mold release agent
• 0.3x1.52m (0.33x1.66yds) of Peel Ply
• 2 pairs latex gloves, 4 mixing pots, 4 mixing sticks
• 4 laminating brushes 1/2" (12mm)
• 1 sheet of 120, 240, 400, 800 and 1200grit Mirka Wet and Dry Abrasive Paper
• 50g (1.7oz) NW1 Black Polishing compound