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 the Composite Materials and Materials Acquisition document first so you have the materials prepared for the process. 

Mold Prep

1. Sanding: We want the mold to be as smooth as possible. Sanding gives a clean finish
   1. Spackling
2. Apply Joint Compound: Joint compound seals the mold
   1. This needs to be lathered all over the mold in 3 layers. Miss no spots
3. Apply Primer: this seals the mold 
   1. Use paint rollers; this will give an even coat of primer
4. Apply mold release
   1. In the past we have used PVA. Historically this has rarely worked on a foam mold.
5. Gather consumables
   1. Gloves: protection from resin
   2. Disposable aprons: protection from resin
   3. Stir sticks
   4. Paint brushes: used to apply resin
      1. Cheap and disposable. Don't reuse these
   5. Buckets: to hold the resin
   6. Scales: to measure the resin
6. Know who is coming to help
   1. Send out an announcement at least a week beforehand asking for people to come help. 
   2. Send out a SignUpGenius so that people 
   3. Make sure they have the required PPE (respirators)
   4. Assign them roles
      1. Resin mixers
      2. Resin appliers
      3. Fabric appliers
      4. Overseers
   5. 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

1. Ensure everyone is wearing PPE correctly
   1. Check respirators to make sure there is no leakage
2. Mix resin and hardener together according to the ratios given on the TDS or on the packaging *Note, many packages give volumetric, make sure the ratio you are using is by weight as this is more accurate
3. Apply resin with paint brushes in thin coats that are the size of the first piece of cut reinforcement
4. Tack down the reinforcement 
5. Add the resin necessary to saturate the reinforcement
6. Use scrapers to scrape excess resin out of the reinforcement
7. Move around the mold and repeat steps 2-6
8. Apply peel ply
9. Apply breather
10. Apply vacuum bag

Common issues

Related articles

• Page:
  2022-2024 Composites Layup Process
• Page:
  Brief Overview of Composite Materials
• Page:
  Resin Infusion 101
• Page:
  Laser Cutting
• Page:
  Aeroshell Wet Layups for Dummies