Step-by-step guide
Preparation
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- For S22-S24 we used foam molds to make a fiberglass tool.
- Reinforcement needs to be precut beforehand to the right size
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Hi, I'm Elizabeth (Maylin) Rawson, the 2023-2024 Aeroshell lead. I made this article based on my own experience as lead conducting and managing the composite manufacturing of Daybreak (2022-2024). This document is primarily for aeroshell management to know the entire process on how to choose and acquire materials, prepare for a layup, and conduct a layup. This is also helpful for general aeroshell members to understand how we choose materials and how layups work. This is the second part of a two-part article: reference my gathering materials document first so you have the materials prepared for the process.
Mold Prep
- Sanding: We want the mold to be as smooth as possible. Sanding gives a clean finish that's close to the CAD and makes it easier to demold
- Spackling
- Apply Joint Compound: Joint compound seals the mold
- This needs to be lathered all over the mold in 3 layers. Miss no spots
- Apply Primer: this seals the mold
- Use paint rollers; this will give an even coat of primer
- Apply mold release
- In the past we have used PVA. Historically this has rarely worked on a foam mold.
- Gather consumables
- Gloves: protection from resin
- Disposable aprons: protection from resin
- Stir sticks
- Paint brushes: used to apply resin
- Cheap and disposable. Don't reuse these
- Buckets: to hold the resin
- Scales: to measure the resin
- Know who is coming to help
- Send out an announcement at least a week beforehand asking for people to come help.
- Send out a SignUpGenius so that people
- Make sure they have the required PPE (respirators)
- Assign them roles
- Resin mixers
- Resin appliers
- Fabric appliers
- Overseers
- If you know that this is going to take a long time, you need to know who is staying overnight and plan out a sleep schedule for these people. to plan out a sleep schedule for every single member and send out a bunch of announcements beforehand that you need hands.
Conducting the layup
- Ensure everyone is wearing PPE correctly
- Check respirators to make sure there is no leakage
- Mix resin and hardener together according to the ratios given on the SDS or on the packaging
- Apply resin with paint brushes in thin coats that are the size of the first piece of cut reinforcement
- Tack down the reinforcement
- Add the resin necessary to saturate the reinforcement
- Use scrapers to scrape excess resin out of the reinforcement
- Move around the mold and repeat steps 2-6
- Apply peel ply
- Apply breather
- Apply vacuum bag
Common issues
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