For more composites related knowledge check out: www.darkaero.com/knowledge/composites/ Want even more? We also offer consulting: www.darkaero.com/consulting
As someone who had worked in composites industry since 2005 it makes me happy seeing so many people enjoy this type of work. I’d love to get back into carbon fiber work
I only recently learned about the galvanic corrosion that occurs between carbon and metals (Mike Patey) and immediately thought of your aluminum honeycomb structure. Happy to see that you have addressed the issue as well. Also that honeycomb looks awesome through the fiberglass turtledeck.
thank you for the easy explanations with argumentation. For the next project you could use thin ply topology optimization, in which thin layers of unidirectional carbon fiber layers in different angles (you can search carbon fused deposition or automated fiber placement , which only modulates the angles of layers, not the thickness) and also different areas, what gives different thickness in any area. You can use an diy arduino machine similar to cnc to apply the plies and then wrap it around the shape you want to make with vacuum bagging. Also in the case of honeycombs, 2, 3 or 4 cores of 5mm gives more strength that one core of 10, 15 or 20 mm, like an onion and an orange. You can use also your own honeycombs made of thin ply carbon fiber oriented 90º, inserted in a mold that gives half the honeycomb structure and then gluing together, an also you can make tetrahedral honeycomb cores, using a layer of foam tetrahedrons and placing continuous carbon fiber only in the edges with a 3d printer. Tetrahedral cores give more strength and weight ration than honeycomb cores and if you stitch (stitching and weaving is necessary in composite construction) the edges of the tetrahedron to both sandwich layers it reduces risk of delamination and add strength too, what in the end, reduces the amount of carbon fiber layers of the sandwich, reducing weight overall with a better laminated structure.
Thank you for explaining the actual properties & differences in each weave type. I knew they had different strength & application characteristics. But Ive been staring at pictures of the Mclaren 720s chassis, trying to figure out how its made.. and why they used 2x2, 4x4, multi-axial, (and what appears to be forged). This explained a lot of the questions I had😅👍
This is the best video I've seen on carbon fiber. I'm curious on any information on carbon kevlar hybrids and what and where would they possibly have an advantage.
How do you impose fiberglass (or some other insulator) to prevent metal fasteners from galvanically corroding to through holes in carbon composite panels?
Avoid fasteners first. If you need to, stainless steel fasteners are not a big issue in carbon fiber, and titanium as well if it's feasible. Mike Patey's Scrappy build is carbon fiber on steel frame, so there's probably some good information on his videos about this. Other than that, fiberglass flanges or brackets incorporated into the carbon fiber would work if the design made sense.
It’s layed up along side the carbon so when you say do a 5 ply layup if you know something metal is going to be fastened onto it you add a ply of fiberglass to the side which it’s going to be fastened too
Be cool to see a video from start to finish on making a foam plug on the CNC to making the plug mold and carbon fiber infusion and carbon fiber finishing. List the materials being used foam for the plug, foam plug sealing compound etc. Like the channel!
I love the engineering around all of this!! Thank you for breaking some stuff down for us? Any thoughts on using Carbon fiber+ peek 3d printed parts being aerospace-grade?
Interesting. When the wing structure is stiffened by selection of carbon fiber as a build material, I assume it then transfers (and concentrates?) the load to the spar attach points?
Thanks & its really are the great walkthrough videos of the project with jam packed key informations. could you please tell me the carbon fabric specification of twill or plain "sleeve" which could be sufficient to make cylindrical rollers of about 20inch...
Hey, I'm just watching through some of these videos. Why did you choose fiberglass, rather than Kevlar for galvanic corrosion? Is it just cost? Are there areas where Kevlar would make more sense?
I'm absorbing all these videos. I love the fact you guys are keeping public face with these videos. Turning them into a overview lesson into the basics of design decisions for the kit is awesome. I can't wait to be a full supporter of the project.
Hi Reverend! We have considered using Kevlar since it is lower density than fiberglass so there are some potential weight savings there. Kevlar has some disadvantages as far as working properties so we used fiberglass for manufacturability reasons. Fiberglass is easier for a builder to cut, trim, and sand compared to kevlar. I think we would probably explore something like Innegra before using Kevlar. Thank you for watching!
Cool videos)) You guys are great, you do cool work) But you do not know, there is carbon fiber with integrated metal threads or fibers, for maximum strength?))
after watching this video and the sandwich panel video i am really wondering how the sandwich panels are “glued” or installed in the airframe whats the process?
That's interesting. So is it safe to assume an epoxy coated carbon fiber piece, that is touching aluminum will not corrode? Or will it still, thus requiring insulation of some sort.. In my case a thin rubber gasket would suit the requirements ( i.e. automotive )
Thank you so much! I just need help with which carbon fiber weave will be strongest when it comes to bending strength? I'm looking at a sheet thickness of 0.50mm and about 110mm x 84mm in length and width.
I’ve seen many aircraft with antennas on the bottom to pick up ground based sources better. Do you have all antennas under the fiberglass top of the canopy?
Hi Tim! The hex pattern you see in the canopy fairing is actually the core material which is known as Soric. The fiberglass becomes translucent when it is infused with epoxy resin and the core material can be seen through the skins.
For more composites related knowledge check out: www.darkaero.com/knowledge/composites/
Want even more? We also offer consulting: www.darkaero.com/consulting
This is probably the fastest way to get your head around carbon fibre decision making. Awesome, thanks guys!
As someone who had worked in composites industry since 2005 it makes me happy seeing so many people enjoy this type of work. I’d love to get back into carbon fiber work
This was amazing. My motorcycle is going to be all carbon fairings. Learned a lot from this
I only recently learned about the galvanic corrosion that occurs between carbon and metals (Mike Patey) and immediately thought of your aluminum honeycomb structure. Happy to see that you have addressed the issue as well. Also that honeycomb looks awesome through the fiberglass turtledeck.
Great overview. Had an aha moment on balancing when the spinner was explained.
Always like learning new things....showing some lay ups would be nice, too! Cheers
I'm so happy to have found your channel. Absolutely amazing!
I have made my own plate and sheet using both Carbon fabric and Fiberglass fabric, Thank you for your contribution.
thank you for the easy explanations with argumentation. For the next project you could use thin ply topology optimization, in which thin layers of unidirectional carbon fiber layers in different angles (you can search carbon fused deposition or automated fiber placement , which only modulates the angles of layers, not the thickness) and also different areas, what gives different thickness in any area. You can use an diy arduino machine similar to cnc to apply the plies and then wrap it around the shape you want to make with vacuum bagging. Also in the case of honeycombs, 2, 3 or 4 cores of 5mm gives more strength that one core of 10, 15 or 20 mm, like an onion and an orange. You can use also your own honeycombs made of thin ply carbon fiber oriented 90º, inserted in a mold that gives half the honeycomb structure and then gluing together, an also you can make tetrahedral honeycomb cores, using a layer of foam tetrahedrons and placing continuous carbon fiber only in the edges with a 3d printer. Tetrahedral cores give more strength and weight ration than honeycomb cores and if you stitch (stitching and weaving is necessary in composite construction) the edges of the tetrahedron to both sandwich layers it reduces risk of delamination and add strength too, what in the end, reduces the amount of carbon fiber layers of the sandwich, reducing weight overall with a better laminated structure.
Thank you for explaining the actual properties & differences in each weave type. I knew they had different strength & application characteristics. But Ive been staring at pictures of the Mclaren 720s chassis, trying to figure out how its made.. and why they used 2x2, 4x4, multi-axial, (and what appears to be forged). This explained a lot of the questions I had😅👍
Really amazing work and brilliant explanation 👏👏👏. Learning a lot from you. Extremely thankful to you.
You guys are really winning me over. These videos are awesome. Thank you for sharing this journey! I may very well become a customer.
As usual, very informative and fun to watch. You guys are real pro's !!
This is the best video I've seen on carbon fiber. I'm curious on any information on carbon kevlar hybrids and what and where would they possibly have an advantage.
I was always curious how you stopped galvanic corrosion from your carbon fiber and aluminum honeycomb. Thanks for the video, keep up the great work!
Wow. Such a informative video about carbon fibers. Thanks
How do you impose fiberglass (or some other insulator) to prevent metal fasteners from galvanically corroding to through holes in carbon composite panels?
I'm curious about this too.
Avoid fasteners first. If you need to, stainless steel fasteners are not a big issue in carbon fiber, and titanium as well if it's feasible. Mike Patey's Scrappy build is carbon fiber on steel frame, so there's probably some good information on his videos about this. Other than that, fiberglass flanges or brackets incorporated into the carbon fiber would work if the design made sense.
It’s layed up along side the carbon so when you say do a 5 ply layup if you know something metal is going to be fastened onto it you add a ply of fiberglass to the side which it’s going to be fastened too
Rick, we recently made a video detailing how we prevent galvanic corrosion. The link to that video is here: th-cam.com/video/yRpMZaU8zKw/w-d-xo.html
Be cool to see a video from start to finish on making a foam plug on the CNC to making the plug mold and carbon fiber infusion and carbon fiber finishing. List the materials being used foam for the plug, foam plug sealing compound etc. Like the channel!
Thank you, 7mins packed with really useful information!
I love the engineering around all of this!! Thank you for breaking some stuff down for us?
Any thoughts on using Carbon fiber+ peek 3d printed parts being aerospace-grade?
I am researching what carbon fiber I will need for skinning a tubular airframe instead on using cloth
Fascinating, Ryley! Thanks for the explanation.
Excellent as always. I learned something. Thanks for sharing!
Interesting. When the wing structure is stiffened by selection of carbon fiber as a build material, I assume it then transfers (and concentrates?) the load to the spar attach points?
Very informative and enjoyable video! One question: do you use Kevlar? Why or why not? Thanks!
Thanks & its really are the great walkthrough videos of the project with jam packed key informations. could you please tell me the carbon fabric specification of twill or plain "sleeve" which could be sufficient to make cylindrical rollers of about 20inch...
Would like to see your process when infusing the carbon fiber sheets with resin. Cool stuff.
look at th-cam.com/video/EwLg50yiR10/w-d-xo.html or th-cam.com/video/ZEmmMAJfe98/w-d-xo.html
Hey, I'm just watching through some of these videos. Why did you choose fiberglass, rather than Kevlar for galvanic corrosion? Is it just cost? Are there areas where Kevlar would make more sense?
How do you keep those fasteners that are exposed behind you in the video from corroding? Different metal?
I'm absorbing all these videos. I love the fact you guys are keeping public face with these videos. Turning them into a overview lesson into the basics of design decisions for the kit is awesome. I can't wait to be a full supporter of the project.
Thank You for shearing.
Have you thought of using Kevlar in place of the fiberglass near the antennas??
Hi Reverend! We have considered using Kevlar since it is lower density than fiberglass so there are some potential weight savings there. Kevlar has some disadvantages as far as working properties so we used fiberglass for manufacturability reasons. Fiberglass is easier for a builder to cut, trim, and sand compared to kevlar. I think we would probably explore something like Innegra before using Kevlar. Thank you for watching!
@@DarkAeroInc thats cool i was just curious wasnt sure how much harder it would be to work vs other composites
Great video. Can you please review the application of the aluminum honeycomb core material?
Might have missed it, but do you bake your carbon parts in-house?
Great explanation!
Where would one get carbon fiber sleeve large enough to lay a spinner up?
Cool videos)) You guys are great, you do cool work) But you do not know, there is carbon fiber with integrated metal threads or fibers, for maximum strength?))
after watching this video and the sandwich panel video i am really wondering how the sandwich panels are “glued” or installed in the airframe
whats the process?
great video thanks!
well done, great info!
That's interesting. So is it safe to assume an epoxy coated carbon fiber piece, that is touching aluminum will not corrode? Or will it still, thus requiring insulation of some sort.. In my case a thin rubber gasket would suit the requirements ( i.e. automotive )
Where each carbon fiber are from and what are their ordering number? I really need to know. Please!
Thank you so much! I just need help with which carbon fiber weave will be strongest when it comes to bending strength? I'm looking at a sheet thickness of 0.50mm and about 110mm x 84mm in length and width.
Is it the same type of carbon fiber use to make mountain bike frames?
I’ve seen many aircraft with antennas on the bottom to pick up ground based sources better. Do you have all antennas under the fiberglass top of the canopy?
Great to share and learn😁awesome video👍
Does the skin have any metal mesh for lightning protection?
Great stuff! Do you make your own sandwiches while you lay them up in the mold?
On that spinner sleeve is there only one open end? (Woven like a bowl not a tube?)
It seems like you would be creating a capacitor too. I don't know how dangerous it would be to electronics if it discharged somehow.
which meterial should be used to make carbon fiber tube ?
Where do source your carbon fiber fabric from?
thanks for this, very well explained- whats the hexagonal (?) shape under / in the 2x2 finreglass twill?
Christian, thank you for checking out the video! We have information on the cloth types on our website: www.darkaero.com/knowledge/composites/
Awesome video
What about lightening 1,000,000+ volt protection?
how can I get the spread two plain please
Informative
We're do u get raw materials
thanks!
very nice vid
Great video! But you left one question unanswered: will it blend?
Is the hex pattern on the canopy some sort of mesh antenna ??
Hi Tim! The hex pattern you see in the canopy fairing is actually the core material which is known as Soric. The fiberglass becomes translucent when it is infused with epoxy resin and the core material can be seen through the skins.
Ничего не понял. Но очень интересно. Спасибо за титры под видео.
Dude you look like Patrick Fabian
Do you make your own tubes?
That's not carbon mate, only you know what that really is 😉
You shouldn’t really hold the cloth with bare fingers.