Creating a Future for Engineers

Formula Student Germany

Wet laminated CFRP monocoque
Manuel Baumann amz.ethz.ch
Creating a Future for Engineers
Introduction
Creating a Future for Engineers
Mold manufacturing
Part manufacturing
Additions
Potential
Bill of Material
Timeline
Index
Creating a Future for Engineers
Positive molds
Laminated negativ molds
Wet laminated monocoque
Bonded halves
Mold manufacturing Concept
Creating a Future for Engineers
Mold manufacturing Molding material
MDF PU Aeroboard 70
Density 800 kg/m 630 kg/m
Thermal expansion 7.5*10
-6
46.8*10
-6
Thermal resistance >100 93
Cost
500 EUR/m
8000 EUR/m
Disadvantage MDF
Inhomogeneous density over thickness
Sensitive to humidity
Creating a Future for Engineers
Mold manufacturing Positive molds
Bonding
Creating a Future for Engineers
Mold manufacturing Positive molds
Milling
Creating a Future for Engineers
Mold manufacturing Positive molds
Sanding
Creating a Future for Engineers
Mold manufacturing Positive molds
Priming
Creating a Future for Engineers
Mold manufacturing Positive molds
Bolts for insert positioning
Internal thread
Creating a Future for Engineers
Material choice: CFRP
Alternative material: GFK
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer:
Epoxy
Fibreglas
Flocs
Thixotropiermittel
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
600 gr/m
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Connection layer
6 Layers carbon fibre
Vacuum
Demoldi
Mold manufacturing Negative molds
Creating a Future for Engineers
Formenharz P
Connection Layer
6 Layers Carbon Fibre
Vacuum
Demold
Finished mold
Mold manufacturing Negative molds
Creating a Future for Engineers
Core material:
Divinycell HP 60 foam
Insert material
Carbon and wood
Part Manufacturing Material choice
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Part manufacturing Monocoque halves
Creating a Future for Engineers
2 core layers of 5mm
Heat bending
Vacuum bonding
Sanding
Part manufacturing Monocoque halves
Creating a Future for Engineers
Mold release agent
Frecote
Part manufacturing Monocoque halves
Creating a Future for Engineers
Mold release agent
Frecote
Resin: Hexion L 235
Hardener L236
Microballons for filling the gaps

Part manufacturing Monocoque halves
Creating a Future for Engineers
Procedure
4 layers CFRP
Placing core / inserts
12 h vacuum
4 inner layers CFRP
15 h vacuum
12-20 h curing at 80

Part manufacturing Monocoque halves
Creating a Future for Engineers
Bonding
the halves

Part manufacturing Joining upper and lower halves
Creating a Future for Engineers
Roll hoop


Part manufacturing Additional structural parts
Creating a Future for Engineers
Roll hoop
Rib

Part manufacturing Additional structural parts
Creating a Future for Engineers







Weight: 21kg (without rollhoops)

Part manufacturing Result
Creating a Future for Engineers
Painting
Degreasing
Primer
Sanding
White color
Sanding
White color
Clear varnish
4kg


Part manufacturing Additional structural parts
Creating a Future for Engineers
Prepreg Monocoque: -Temperature resistant resin for negative molds
-Same manufacturing process

Advantage: Less weight, better surface, no painting needed
Additions Potential
Creating a Future for Engineers
Additions Bill of material
Material Amount Price
CFRP 600g/m
2
for negative molds 30m
2


1200EUR
CFRP 250g/m
2
for monocoque 40m
2


1400EUR
Foam Core 5mm 6m
2
300EUR
MDF 0.8m
3
500EUR
Resin 35kg 600EUR
Vacuum material 300EUR
Total 4300EUR
Creating a Future for Engineers
Important:
Well organiced workspace for laminating and sanding
2-4 people needed during laminating (due to little pot-life)

We used 8 weeks, mostly one person for positive molds, negative molds and
monocoque

Additions Timeline
Creating a Future for Engineers

05. 09. August 2009
See you at Hockenheim