5 Axis Filament Winder
Filament winding is a process that can be used to create round fiberglass shapes with exceptional strength characteristics. Used for piping, tubing, and tanks, filament winding is normally an automated process that has computer-controlled equipment to place glass and resin around a mandrel- the piece that functions as the mold.
There are many variables that can be modified for filament winding, and these will affect the strength characteristics of the finished piece. The angle of the glass, number of passes (thickness), use of glass mat, and type of resin will affect the finished product strength characteristics.
I found a short video that demonstrates the equipment and the process.
As you can see, the glass is applied in a consistent manner across the part, allowing for uniform strength characteristics. As you can see, this is yet another process that the composites industry uses to create useful products with advantages over those of competitors.
Vacuum Bagging Video
Vacuum bagging is a process that requires unique materials and processes, but can be simple to operation in an ongoing basis.
There are many advantages to vacuum bag molding, a few of which include:
- Improved resin/glass ratio
- More consistency across the laminate and part -to -part as compared to open layup
- Containment of air emissions from the resins
As compared to hand layup and chop layup, there are a few disadvantages, including
- Higher consumable material cost
- Higher capital equipment cost
- Difficulty with superior surface finish
Some parts are more suitable for vacuum bag molding than others. It also depends upon which process it is being compared with.
Vacuum bag molding requires an extremely tight seal between the mold and the bag. Molds with multiple pieces or holes for inserts can be difficult to complete a seal.
Parts that are overly large and complex can present challenges with placing resin and reinforcement before the cure cycle starts. The bag must be completely sealed and under full vacuum before the curing cycle of the resin begins.
The basic premise of vacuum bag molding is that the air is removed from the bag, allowing the atmosphere (air on the outside of the bag) to push the bag onto the part on the mold, compressing the layers of resin and reinforcement. Many misinterpret the process as “sucking the extra resin out.” We are merely allowing the laminate to be compressed by the weight of the air above us in the atmosphere to consolidate it before cure. The excess resin is usually absorbed by extra layers of sacrificial material inside the bag.
Composite Dock
Building outdoor structures around water require special considerations. Wood rots, steel rusts, and dirt erodes. Fiberglass composites have been making strides in uses for marine-related activities. Round fiberglass pilings can replace wood pilings, and sheet pilings made of steel can be replaced with fiberglass retention walls.
The fiberglass composites have several advantages. They have a much longer service life because they do not rot or corrode. Compared to wood structures, they are more uniform in size. They are typically lower in weight to allow for lower lifting, handling, and transportation load requirements.
All of these advantages are used by a company called Green Heron Docks that builds docks in a “green” manner. Their docks are build from the previous dock sections, allowing for minimal interruption of the surrounding environment. Their installed docks will have a long life that will not require replacement related disturbance for time to come.
Their video on Youtube
As you can see, their equipment is relatively lightweight and inexpensive compared to bringing in cranes and barges. Their environmental impact is minimal, and the resulting product has a very long service life that will endure for years to come.
Liquid Bulk Transport Tanks
Lincoln Composites has introduced their Titan™ Liquid Bulk Transport tank. This unit is comprised of four composite tanks that meet the specifications of a universal shipping container, allowing for transport via ship, rail, or semi on existing infrastructure.
TITAN Gas Transport
The tanks are require three basic parts to complete the engineering challenge. An inner liner made of High Density Polyethylene provides an impermeable layer to hold the gas. Next, a filament-wound composite shell made with epoxy and carbon fiber contains the pressure of the gas. A Polyurethane coating on the outside of the tank protects from moisture and abrasion.
The system is designed for Natural Gas, Hydrogen, Argon, Helium, Nitrogen, etc. Existing transport via semi truck is accomplished with large steel-tanked semi trucks that are heavy and prone to corrosion. The TITAN composite solution allows for multiple transport options (rail, ship, semi) as well as lower tank weight. The gas stored versus the tank weight is a huge advantage over steel tanks.
Lincoln Composites claims that traditional steel tanks hold 4000 SCM less CNG than the TITAN™ and weigh 16,000 kg more than the TITAN™ composite tanks.
For more information, check out the Titan page at Lincoln Composites.
Machining Composites CNC Video
Much like other materials can be machined, so can composites. Everything from basic fiberglass fabrications to advanced composites materials can be machined to add details and features.
This can be accomplished using hand-held tools guided by fixtures and measurements. Hand tools such as air routers, drills, and saws. A disadvantage is that the operator can commit errors and must be protected from safety hazards. These hazards include airborne dust, bending strain, lifting strain, and physical cuts.
For high volume or high precision applications, there are CNC routers that can be employed. These are fast, efficient, and safe. They may be expensive though.
Several manufacturers make CNC routers, and Thermwood is one as shown below.
This video shows several different applications and parts that can be routed with this large Computer Numerically Controlled machine.
Carbon Fiber in the Chevrolet Silverado ZR2 Concept
At the 2009 Las Vegas SEMA show, Chevrolet introduced their ZR2 Concept pickup truck. This truck is tricked out for off-road capability with all wheel drive and a tricked out suspension. Weight savings improves performance and the designers turned to carbon fiber composites.
Exterior body panels were improved by saving weight by using carbon fiber. These panels include the hood, fenders, tailgate, grille, fascias, fender flares, and rocker panels. The hood and tailgate have used clear-coated carbon fiber to show the weave and give an interesting two-tone look to the vehicle.
The interior is also reported to use carbon fiber in the dash and the door panels.
It is unknown whether this concept vehicle goes into production, but certain elements are certainly becoming mainstream. Aftermarket carbon fiber parts have been popular for years especially on tuner cars. This may catch on for mainstream OEM production. Carbon fiber parts save weight, do not corrode, do not dent, and do not require pigmented paint.
Moldless Car Body
Building a custom car body with fiberglass can be achieved without using a mold! This will be a truly custom, unique vehicle. It will take lots of planning and hands-on work, but is very possible as shown in these YouTube videos.
There of course are several ways to go about building a basic structure to use for the basic shape. This video gave lots of good ideas and examples of materials that are relatively inexpensive.
The second part of the video shows some of the actual fiberglass work. This video of less than eight minutes does not nearly do justice to the amount of work and effort that went into finishing this project! It was great that the author documented his work and shared with all. This was a major project that is not for the faint of heart.
He does a very good job explaining the process and materials used in this construction. Every project is unique, however. When discussing the thickness of the fiberglass skin, there are many variables that determine the finished strength. The number of layers to use is dependent on the amount of underlying support structures, part geometry, and required load bearing capacity of the structure. Some areas may need to be stronger for impact resistance and structural loads.
The video author discusses only using epoxy resin with Styrofoam as opposed to polyester resin which will react with the Styrofoam. Polyester resin can be used if separated from the Styrofoam with an additional layer. While I have only seen it advertised, there are new spray on primer materials available to cover the Styrofoam and allow polyester resins to be utilized afterward.
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