Carbon Fiber - 5 things you (probably) didn’t know
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- Опубликовано: 31 май 2024
- Learn how to make your own high-quality carbon fiber parts: darkaero.com/courses
Before we started building the DarkAero 1, we had to learn a lot about carbon fiber. I want to share with you some important information about this material that will give you a better understanding of it, especially if you want to engineer a part made from carbon fiber.
This video covers 5 important things you need to know about carbon fiber.
1) Not all carbon fiber is created equal
- Carbon fiber is made up of small filaments. There are different "types" of filaments of different degrees of strength and stiffness. Additionally, there are different grades of cloth which determine the number of defects in your cloth weave. It’s important to understand what “type” and grade is right for your project.
2) Resin is the unsung hero
- It's easy to focus on the carbon fiber alone. However, you need to pay equal attention to the resin used. The resin allows carbon fiber parts to hold their shape and transfer load from one fiber to the next.
3) Carbon fiber is coated with a secret sauce
- Carbon fiber manufacturers will add a coupling agent (aka "sizing" or "finish") to filaments. This coating helps the resin bind to the carbon fiber. Without the coupling agent or proper coupling agent, the strength of your parts can be reduced.
4) Process drives properties
- The process (wet layup, prepreg, infusion, etc.) you select will ultimately partially determine the properties of your part. Process drives fiber to resin ratio and part defects. Understand which process makes most sense for the goals of your carbon fiber part(s).
5) Test or be tested
- Because there are so many variables that go into carbon fiber, there aren’t good sources of published material properties available to use for design. This means you need to perform testing to verify your parts meet the desired requirements.
Intro - 00:00
Not All Carbon Fiber Is Created Equal - 00:37
Resin is the Unsung Hero - 03:10
Carbon Fiber is Coated with a Secret Sauce - 05:15
Process Determines Properties - 06:24
Test or be Tested - 08:10
Outro - 09:43
Read more this subject here:
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DarkAero Composites Manufacturing Overview
www.darkaero.com/knowledge/co...
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What are other interesting facts you have learned about carbon fiber? What aspects of carbon fiber would you like to learn more about?
I would be curious to see a detailed "how to" for infusion molding, drawing on what you outlined in this video.
What is the weight ratio of the carbon fiber to the resin for a finished part?
@@chicosajovic7680 roughly 70% carbon to 30% resin by weight. These numbers vary by +/-2% based on the specific part, weave type, and fiber orientation in the part.
Inserts ,fixings, etc and UV protection.
@@DarkAeroInc That seems a bit on the dry side. Have you ever tested this? I work with prepregs and the data sheets usually say about 60% fiber 40% resin (by weight).
I’ve just found your channel. I can’t believe how incredibly professional and thorough your work is. And I am even more impressed by your generosity in creating these professional videos and sharing your knowledge with the world.
Neil, thank you for the kind words and for checking out the channel! Glad the videos have been helpful!
I am full time in carbon Fiber manufacturing. Gayford Carbon Fiber Strad Violins. This is without a doubt one of the best intro's to carbon fiber videos I have seen. I can tell you have a mastery of the properties. Well done! I will start following your aircraft build as I have a Carbon fiber aircraft. A SkyArrow. PS I see you have two thumbs down, obviously some who think Carbon Fiber is spelled "Carbon Fibre" LOL
I read your post as “gaylord” instead of “gayford” 😂
I mean, it is spelt fibre rest of the world. The most advanced composite and carbon fibre manufacturing facilities and technology are based in Europe.
The United States is the only country where it’s called “called fiber.” The rest of the world writes it as “fibre.” Typical American thinking they’re always right 😂 And this is coming from an American
It’s like the difference between “cell phones” and “mobile phones”. The tech for cell phones was developed by what would become Qualcom in San Diego California USA. Equally, Carbon “fiber” developed for aircraft parts were developed by Douglas Aircraft and Lockheed Martin Aircraft in Southern California USA. Just because these materials and processes were eventually marketed to the World does not mean that their original names should not be respected
Your methodical detailed design approach is admirable and impressive. Shows you have determination and patience required.
THE RESIN YOU USE IS JUST AS IMPORTANT!!!!
THANK YOU for stating what I've learned from years of composites experience - Test, test, and more testing!! The only way to verify results is to mechanically test EVERYTHING. Great overall presentation and thanks for mentioning fiber/resin compatibility as well - a hidden key to composites success or failure. If you've done coupon level testing on any of your laminates, I'd be very interested to know the mechanical properties you've been able to achieve.
Thank you! Testing is key!
Imbok - do you do testing of carbon fiber sub assemblies today? Is that a service you offer? What is the fee?
Sorry I can't even pay attention to what you're saying, that profile view of DarkAero 1 looks sooooo good at 13 seconds in and I can't get it out of my head
When i saw the profile for the first time, I thought of the original Ford Mustang styling. Not sure if they’re even similar but something about it reminded me of the extremely appealing mustang design
DART Aero > DARK Aero
Best short summery so far I watched on yt regarding CFRP. Good job!
Can't wait to see it in person...must...find...cash....tree
Excellent presentation, I found it very useful. Thank you.
You & your fellow engineers are amazing! Keep up the great work,we'll be watching. Thanks much for the insight!
Thanks for taking the time to share what you have discovered. I have been dreaming about making my own plane for years but keep finding excuses. Your DarkAreo project is very inspiring. Thank you!
I've been into carbon fiber for about 20 years and this has been a really fascinating video. Learned a lot here and everything was nice and clear. Great job
Very.good, this is the best series of videos on CF I have found, thanks for doing this!
I LOVE YOUR CHANNEL. PLEASE CONTINUE TO SHARE YOUR TRUTH.
Very clear presentation. Thank you for sharing what you are learning and doing.
Fantastic project. Thanks for taking the time to share this with the world. 🇨🇦
Thank you so much! I'm always impressed by your infusions :)
Thank you!
wow you knocked it out of the park on this video. thanks a ton
Great presentation. Thanks!
Awesome! thanks for sharing this
excellent video, well presented with all applicable points covered short and simple.
Great information, well presented!
THANK YOU SO MUCH!!!! A MUST WATCH!!!
Very cool. Thanks for sharing your knowledge gents.
As always great and easy to understand info, keep it up 👍
Very informative, accurate and relevant vid.
Thx, from France
YES! Its like the engineering explained version that focuses just on carbon fiber and how to actually make stuff!
Thank you for these information rich videos. Clear and concise.
I look forward to learning from many of your other videos.
Quality content!--You've earned a new design engineering subscriber!
Great info. Thanks!
Thanks for the very insightful video!
Great video. Went from super simplification of carbon fiber all the way to the spec sheets.
This was very interesting and informative. I've been riding a carbon fiber bike for the last 15 years. Thank you.
Very informative video. Thank you
Superb Video with Great Technical information that we have used in our Orthopaedic Laminating Procedures for our Patients, please keep putting them on RUclips so we can get the very best Prosthetic Builds for our Customers.
Extremely detailed and well informed video! I used to be on an aero team myself, all of this is legit. 👍🏼
Outstanding info!
Short but informative 👍🏽 thank you very much 🙏🏾
Quality work! I’d love some more testing details. Process, Test conditions etc. Absolutely love your channel!!
Very nice video! Presenting the big picture so clearly is not easy.
Well presented! Thanks.
Awesome - my composites knowledge is limited to spat repairs on my RV-8, this is another level of information that really demonstrates your high level of expertise. I just wish you guys were in the UK.
Great info! Thank you!
Thank you, it is very useful.
Well done, content presentation, information provided. Very informative and interesting.
Great videos. Thanks.
Well you could have touched on The orientation of the weaves of the material when you lay into the mould for the strength and flexibly of the parts.
I work at Toray. It is definitely a unique process.
Love the info guys! 👌
Thanks for dipping into the weeds on the process and philosophy of carbon construction.
OUTSTANDING PRESENTATION!
Thank you for actually mentioning the more important factors vs the marketing nomenclature regurgitation most channels spit out.
Thanks a lot..Great video
Most helpful 10 min. for my individual research about "carbon fibers in automotive" project for my thesis. Although this video is about on aerospace :) It was really detailed.
-Thanks from Turkey
Thanks for sharing. Tonnes of information on carbon fiber here.
KEEP UP THE GREAT WORK!!!
Thank you, this is amazing information. I just saw a custom carbonfiber lid made for a laptop, and the people saying that carbon fiber is cheap and parts are easily made for a 100 dollars, made my jaw drop, because it's not that easy... not all carbon fiber is equal, this video will help me teach a few people about it.
Clear and helpful video for anyone who wants to learn more about carbon fiber. Keep up the good work
Thank you for watching and for the kind words! :)
Perhaps a vid on various layup techniques in terms of the direction you might run the fibers in different scenarios (corners, flat plate surfaces, access holes curved parts), would be cool to see. Great stuff, guys. Subscribed earlier today! My uncle built (professional pilot) planes - Cub J-3, serial #1 1001-B0200, and has seen his work, so I really appreciate what you are doing!
Fascinating subject and you did a fantastic, great video. Seriously guys, I place this at the top 1% of technical videos on RUclips. THANK YOU!
Dan, thank you for watching and for the kind words on the video! :)
Dan - we should see if @EngineeringExplained would give these guys a guest hosting spot!
Very well done.
This is a nearly perfect introduction to the technical details of carbon fiber parts components creation. Please do write a full book on this.
Great stuff guys... As to other CF related content: I'd love to see the full infusion process for one of the more complex parts, all the technicals i.e. how-to in terms of vacuum specs, resin flow and saturation, baking, finishes/UV sealing or what have you. Alternatively, or rather additionally, I'd really like to see how you guys bond different parts together, for example the bulkheads and the airframe (and maybe how you bond your sandwich panels in the first place)? I'm also curios about the motor mounts or the fuel tank install, basically how you bond CF and metals.
They offer engineering and process consulting services, check out the consulting page on their website.
Excellent video !
Excellent general Engineering advice!
Great good video! All basic stuff but cold converted so everyone understands
One comment about your carbon fiber spinner bulkhead . Make sure that you are using either a high tg ( some can reach 240 degrees C , resoltech ht240) resin , or use high temp prepreg. Otherwise in any direct drive engine front of the crankshaft gets hot, and prop bolts will get loose. That happened many times....
A nice survey of carbon fiber composites. A video on how you meet part 23 certification requirements with regard to structural capability would be really informative, and specifically on the role of analysis in the certification. Nice work!
Great info!
If every teacher would be as good and clear as you guys, lerning would be joyfull!!!
Great video!!! It would be great if you could make a video about the different curing methods
Love watching your videos. Great work guys.
I know it can change, but when do you hope to start test taxis / flights?
Fantastic!
beautiful plane! it is really coming along.
Nice work on both the plane and the channel. Do you use spray adhesives to tack the dry cloth to 1) the mold, and 2) further layers of cloth, before infusion? If so, have you tested with/without spray adhesive to see whether stiffness is affected or delamination is a concern?
Great teaching. Thx.
I love what you guys are doing! Keep up the good work!
Thank you for checking it out! :)
Thank you.
Thanks for the free CF education! I wish you great success. That appears to be a real slippery aircraft. Should do well on fuel consumption.
Great video.
What a great video
I’m looking forward to the future of aviation with great minds like this team getting the resources to make shifts in the aviation future.
In the 1950s the new wonder material was glass fibre. Lotus and Reliant made complete car bodies out of it.
There were two adverse features of glass fibre.
1) the surface was prone to "crazing" under stress.
2) the uncured resin was horrible stuff to come into contact with.
Is this also the case with carbon fibre?
Thank you this was very informative as an aspiring aircraft kit designer. Not that I want a company. This is just for me. None the less, the information and the way you explained it is invaluable.
Thank you for watching! :) Good luck in your kit aircraft designs! It's always exciting to see new designs take flight.
Ok, So I did watch your "Galvanic Corrosion episode" but I did not subscribe because I was new to YT. NOW I am watching DarkAero again and Subscribing for sure my friend! I've been researching to build a CF frame for my DIY motion Sim rig (works great, but now gotta lose the weight) Appreciate all your info ! DMAX motion sim channel
I'm really enjoying learning about carbon fiber from you. I like the scientific approach, and factual data presented. I'm currently prepping some fiberglass pieces to make molds so I can redo them in carbon fiber. In my case, they are just fairings for a bike, so not actually structural, but more education on the material is always a good thing. Thank you!
Glad you are enjoying the videos! We are happy to share lessons learned. Thank you for watching and good luck on your bike fairings! :)
Unless you need stiffness over everything else, S glass grade fiberglass is a better and less expensive material. It actually has a higher tensile strength to weight ratio over commercial/common grade carbon fiber. It's a tougher material that handles impacts and abrasion better as well.
In an airplane, with wings, tale, etc you do need the very high stiffness of carbon fiber, but in many applications you don't really.
Also, when you combine S glass with carbonized cellulose nanocrystals in the epoxy, you up the various strengths at low cost and low weight. I say low cost if you make the material at home. Once you have read through the research, making C-CNC's at home is not that hard to do. But don't be like the industry and use things like waste wood and paper--use a material that is already high in crystalline cellulose. (Tip, many cellulose based natural fibers used for fabrics contain a higher percentage of crystalline cellulose than wood etc).
@@justinw1765 I’m not sure what parts you’re thinking of. I’m not an expert enough to know specifically what s grade fiberglass is vs what I was using, maybe it was. But I can tell you without doubt that fiberglass is only potentially lighter when talking about needing to use a certain amount of material. Like, if you absolutely need the part to be 1/4” thick and solid regardless of material, then fiberglass might be lighter. However if the part just needs to be able to withstand X amount of stress, then carbon fiber is stronger and needs less material, thus, it’s way lighter. While using less material, it can be more flexible. For my motorcycle fairings, the carbon is a LOT lighter, and absorbs impacts much better. It all depends on what qualities you’re after and what specs are important for the particular part or product.
Thank you
Very interesting!
Another great video guys. That definitely answered my question about CF weight. I’m taking Material Properties right now, and working on a project to test the properties of CF, aluminum and balsa wood. Tons of nerd fun haha. What’s the lightest part you’ve made?
How have you integrated metal in the weave for lightening protection? Could you show a video on how you've done that. I saw one video on laying a fiberglass sheets down but what kind of "metal layer" is supposed to be used and where do you buy it or how do you make it? THX
Excellent videos ! Content is super !! Sir where do you recommend to buy resin that performs well on high temperature ?
Thank you, absolutely great and informative video. One could only have hoped that OceanGate would have taken an as professional approach.
Great video, practical course about carbon fiber in 10 minutes.
Thanks for watching! :)
Please tell us more about testing range for different type of parts that are made up with carbon fiber,and also want to know about different method of stiffening it with resin.
Btw this is really awesome stuff💛
An important topic I don't see often on composites is best methodologies for bonding of sub assemblies. For instance, for a carbon fiber tub for a super car for instance, its obvious that they are made of several sub-assemblies that are bonded at critical joints. That may be a good topic for a video. Thanks!
Covered all the bases ,well done! I remember a comment by the teacher I had in an advanced composites course. “ If you get it wrong there will be a pissed off pilot” a voice from the back of the class “ But not for long!”...
Thank for your articulate explanation. Every time I look at your project I wonder if there is a turbine that could be fitted up front. Perhaps your next design will have a high bypass turofan. Very exciting, guys.
So no go on CF wheels? Bending seems better than shattering.
Hello, thanks for a good educational video. What resin do you use for infusion? How many different resins do you use in the construction of this airplane?
I would enjoy seeing you expand on the segment "TEST OR BE TESTED". How did you determine the size and shape of the coupons that you tested? And, how did you choose the particular type of test(s) that would provide you with useful data? What was your sample size? (The number of tests of the same material/process)
And, for those of us who may not have the test equipment of our own, how would we find and select a test lab who would be suitable for this type of testing?
And referring to a previous video, you mentioned that you are producing your own sheets or sandwich materials. How do your materials compared to the materials that you found commercially available?
Your build is fascinating to follow and your knowedge and care is admirable. I have a couple of questions about repairability and survivability: I have heard of carbon fibre airframes being written-off after relatively minor damage, as localised repairs are not feasible in a pressure structure or in a dynamic component. A low speed runway overrun in a Premier jet with little obvious damage resulted in a write-off - and a well-publicized bird strike on the wing of a Premier1 jet which looked minor was deemed uneconomic to repair and the entire airframe was written-off. I realise that DA1 is not a pressurized aircraft, but it is fast. How would say, leading-edge or airframe damage from a bird strike be dealt with? Secondly, there's crash survivability. In the motor racing world, it was realised that carbon fibre can shatter on impact, creating dangerously sharp pieces - and designers had to protect occupants from this in the cockpit design.