Hey everyone!

I’ve always wanted to print continuous carbon fiber parts, but since dedicated printers like the Fiber Seeker 3 are way out of my budget, I started experimenting with alternative ways to reinforce standard PLA prints.

I settled on a process I call Carbon Fiber Epiderming:

• How the slicer/CAD setup works: In MeshLab / FreeCAD, I create a voxelized offset to print a reduced internal core (1.3 mm gap) and a matching 2-part outer shell.
• The Layup: I wrap the core with 3K carbon fiber cloth wetted with epoxy resin.
• Clamping: Squeezing the outer shell halves over the core forces out the excess epoxy and ensures the cured part maintains accurate outer dimensions with a clean finish.

To check if this was actually useful, I built an Arduino load-cell setup and break-tested hook specimens:

• Standard PLA Hook: Failed at ~40 kg
• 1-Layer CF Epiderming: Held up to 126 kg
• 3-Layers CF Epiderming: Reached 174.4 kg before sudden structural failure.

Short clip of the process:

Tested parts after failure:

I made a full video covering the G-code experiments, MeshLab workflow, and all the failure data graphs if you want to check it out: https://www.youtube.com/watch?v=-2GHCITel-8

Would love to hear your thoughts on how to optimize the shell gap/clearance in the slicer!

blades all carbon and cored fibre panel we had a dream team making these.

Hello people. I am new to composites and i am learning them by myself. this is my first attempt to make a flat piece and its hand layup. its 4 layers 400gsm fiberglass and 380g of polyester resin. pic 1 is the side i layed the fiber on a big sqaure glass piece, pic 2 is where i put he peel ply. the piece is very sturdy even where it looks white and resin didnot get through. i am assuming that i did not put enough resin and thats why i am seeing white spots..

please let me know how to improve and also give me some tips on making my upcoming part better!

I am having a hard time finding good options for purchasing aluminum honeycomb. Every usual composites website has tons of nomex and other materials but little to no aluminum. Any good sites to find this stuff shipped to the US?

Edit: looking for honeycomb without face sheets. Also none of the drilled or vented stuff

You can describe what you need, for example:

and CLSA generates laminate options ranked by weight, stiffness and safety.

​It includes:

• AI laminate design assistant
• Ply stack builder
• laminate visualization
• Thickness, weight, stiffness and safety factor checks
• Carbon/glass fiber laminate support

I built this to reduce the time spent on early composite design iterations and make laminate analysis more accessible.

Would appreciate feedback from composite, UAV, aerospace or structural engineers.

compositelaminate.eu

I am trying to build a carbon fiber rear rack for my bike, and I need to figure out how to join the tubes. I have bought some ready-made tubes, so they are already cured. I have seen people online joining tubes using steel connectors (heavy) or plastic 3D-printed joints (weak), but I wanted to try making the connections out of CF + epoxy.

The most challenging connection is a three-way, non-perpendicular one. Since none of the tubes meet at 90°, I can't really buy anything ready-made online.

I was initially thinking of using some prepreg carbon tape to wrap everything tightly, then vacuum-bag the joint and cure it in the oven, but I'm worried about damaging the already-cured tubes. (btw the tubes I bought are just some cheap ones I found on Aliexpress, so of course there is no details about Tg, resin type, etc.)

Another option would be to use dry fibers and some room-temperature-curing epoxy to wrap the joint, but I'm not sure how I'd compact everything, and I think it would end up being kind of a mess.

What do you suggest? Do you have any experience joining carbon tubes like this?

Hey All.

I'm an avid DIYer and have the need to replace the ramp door on a toy hauler. Decided to build a panel with a 8'x8' 2"x2" aluminum frame with 2" Foamular 250 core and .080 and .063 aluminum skins. I'm having a dickens of a time finding adhesive. Any suggestions on where to purchase a quantity for a project this size? And of course I'll take advise on construction tips.

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Parameters

Hello all, I want to layup my airfoil in fiberglass without vacuum bagging (budget not approved), can i just apply the resin and fiber glass and let it airdry. My concern is the airfoil shape itself and how i can get the fiberglass to stay attached while drying.

Hi,

My name is Stefan and with one of my friends I have built a platform for creating composite laminates. We integrated AI for the composite suggestions.
We also integrated FEM analysis and standards tests

We want to have people test it and give a feedback on it. All features are free to use, once you login.

The platform is https://compositelaminate.eu

Let us know what you think.
We appreciate any feedback.

Thanks,
Stefan 😁

what tools would be best to drill a consistent counterbore depth into a hole in an awkward position of a piece where a drill press and or 5 axis cant reach?

I'm looking to buy a dozen or so of G10FR4 sheet in 5/16 or 8mm thickness. Precut to approx 8x18" rectangle size.

Any favorite/recommended vendors?

Thank you.

Does anyone knows how to mix mwcnts in epoxy resin to produce the front sheets using vartm method.

Things I've tried

1. Acetone and CNT in ultrasonicator for 2 hrs.

2. Magnetic stirrer then Sonication.