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FormulaStudentGermanyWetlaminatedCFRPmonocoqueManuelBaumannamz.ethz.chIntroductionMoldmanufacturingPartmanufacturingAdditions

Potential BillofMaterial TimelineIndexPositivemoldsLaminatednegativmoldsWetlaminatedmonocoqueBondedhalvesMoldmanufacturing–ConceptMoldmanufacturing–MoldingmaterialMDFPUAeroboard70Density800kg/m3630kg/m3Thermalexpansion7.5*10-646.8*10-6Thermalresistance>100°93°Cost500EUR/m38000EUR/m3

DisadvantageMDF Inhomogeneousdensityoverthickness SensitivetohumidityMoldmanufacturing–PositivemoldsBondingMoldmanufacturing–PositivemoldsMillingMoldmanufacturing–PositivemoldsSandingMoldmanufacturing–PositivemoldsPrimingMoldmanufacturing–PositivemoldsBoltsforinsertpositioningInternalthreadMaterialchoice:CFRPAlternativematerial:GFKMoldmanufacturing–NegativemoldsFormenharzPMoldmanufacturing–NegativemoldsFormenharzPConnectionlayer:EpoxyFibreglasFlocsThixotropiermittelMoldmanufacturing–NegativemoldsFormenharzPConnectionlayer6Layerscarbonfibre 600gr/m2Moldmanufacturing–NegativemoldsFormenharzPConnectionlayer6LayerscarbonfibreVacuumMoldmanufacturing–NegativemoldsFormenharzPConnectionlayer6LayerscarbonfibreVacuumDemoldiMoldmanufacturing–NegativemoldsFormenharzPConnectionLayer6LayersCarbonFibreVacuumDemoldFinishedmoldMoldmanufacturing–NegativemoldsCorematerial: DivinycellHP60foamInsertmaterial CarbonandwoodPartManufacturing–Materialchoice2corelayersof5mmHeatbendingPartmanufacturing–Monocoquehalves2corelayersof5mmHeatbendingVacuumbondingSandingPartmanufacturing–MonocoquehalvesMoldreleaseagent FrecotePartmanufacturing–MonocoquehalvesMoldreleaseagent FrecoteResin:HexionL235 HardenerL236MicroballonsforfillingthegapsPartmanufacturing–MonocoquehalvesProcedure4layersCFRPPlacingcore/inserts12hvacuum4innerlayersCFRP15hvacuum12-20hcuringat80°Partmanufacturing–MonocoquehalvesBonding thehalvesPartmanufacturing–JoiningupperandlowerhalvesRollhoopPartmanufacturing–AdditionalstructuralpartsRollhoopRibPartmanufacturing–AdditionalstructuralpartsWeight:21kg(withoutrollhoops)Partmanufacturing–ResultPaintingDegreasingPrimerSandingWhitecolorSandingWhitecolorClearvarnish 4kgPartmanufacturing–AdditionalstructuralpartsPrepregMonocoque: -Temperatureresistantresinfornegativemolds -Samemanufacturingprocess Advantage: Lessweight,bettersurface,nopaintingneededAdditions–PotentialAdditions–BillofmaterialMaterialAmountPriceCFRP600g/m2

fornegativemolds30m2

1200EURCFRP250g/m2formonocoque40m2

1400EURFoamCore5mm6m2300EURMDF0.8m3500EURResin35kg600EURVacuummaterial300EURTotal4300EURImportant:Wellorganicedworkspaceforlaminatingandsanding2-4peopleneededduringlaminating(duetolittle