This week we learned how to make composite structures using fiber and epoxy. My goal was to make a small 9in replica of the 14ft Hyperloop vehicle I built earlier this year for Elon Musk's SpaceX-Hyperloop competition II. Didn't come out as good :(
First, we had to mill out the structure we want to make a mold of in the ShopBot. Note the origin is set according to where the Shopbot sees X=0 and Y=0. Add a 0.6in symmetrical buffer around the structure so the ShopBot will mill around the outside.
Set the Roughing and Finishing Toolpath with a 0.5in Bull Nose Bit. Raster along Y in this case to reduce the amount the ShopBot has to move. Spindle Speed, Plunge rate, etc are given by the shop instructor.
Cut out the mold from styrofoam!
Wrap mold in sticky plastic wrap.
Obtain fabric for epoxy time! Ratio is 100:40 for epoxy mix. After drenching all layers over mold, add a plastic paper (with holes) and a cloth fabric around the entire structure.
Vacuum Form!
Finally, trim the edges and you're done. Wished it turned out better, but oh well.
Special thanks to Tom Lutz and Safinah Ali for helping me with this week's work. Now onto the final project!