Model Board Moulds + Resin Infusion for Faster, Lower Cost Prototypes

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Further information and links ▼

This tutorial covers in detail an end-to-end production process that can be used to save time and materials when making complex one-off or prototype composite parts after James from ‪@Project-Air‬ asked Easy Composites to help him design and build a new carbon fibre monocoque for a world record attempt for the fastest jet-propelled RC car.

With a tight budget and short timeframe, we were able to produce this complex part in just a few days and for a fraction of the cost of full-blown production techniques by directly machining the moulds from polyurethane model board and then producing the part using resin infusion.

You can check out ProjectAir's part of the build and see how he got on here:    • Building the WORLDS FASTEST RC Jet Car 3.0  

Related Videos▼

CAD Tutorial for the Mould Design ►   • Practical CAD Techniques for Composite Pat...  
Complete Startup Guide to Resin Infusion ►   • Making Professional Carbon Fibre Parts Usi...  
Copying a Part in Prepreg Carbon Fibre ►   • Complete Process of Copying a Part in Prep...  

Where to Buy Products▼

All of the composites materials and equipment used in this video are available from Easy Composites to support manufacturers large and small around the world with their composite material and equipment needs. Depending on your location, please visit the Easy Composites site for your region:

Customers in the USA ► https://www.easycomposites.us/learnin...
Customers in the EU ►https://www.easycomposites.eu/learnin...
Customers in the UK or Rest of World ► https://www.easycomposites.co.uk/lear...

Chapters▼
00:00 - Introduction
00:34 - Design
01:35 - Designing the Mould
02:58 - Machining the Mould
04:32 - Resin Sealing the Mould
07:15 - Process Selection
11:00 - Reinforcement Layup
15:47 - Closing the Moulds
17:21 - Joining Strategies
19:04 - Resin Infusion Setup
24:55 - Resin Infusion
26:39 - Demould & Trim
29:33 - Painting
30:47 - Analysis