Carbon Fibre Chassis

[Wilko]

This year for the first time the Cardiff Racing team has access to an autoclave and we are considering the possibility of making our chassis from carbon fibre honeycomb. The major concern that would discourage us from doing so is that there is very limited knowledge of the process within our team as the autoclave has only just become available.

It would be useful to get in contact with anyone out there who has done a similar thing. Do you think it would be feasible to manufacture a complex part like a chassis without much experience? Also would you be willing to provide technical advice while we are going through the process and potentially experiencing difficulties? It would be invaluable to have a running dialogue with someobody who has hit these problems before!

Cheers

Wilko

[Chris Lane]

I know UWA here in Perth spent about a year developing their carbon fibre laying processes.

There is a lot to research and develop before you lay up a chassis.

[MalcolmG]

I would suggest that if you can find an experienced and knowledgable composite parts manufacturer who is keen to guide you/bounce ideas off, then you will be capable of doing it - provided you have a couple of very committed team members to run the show and a lot of reasonably committed helpers. Just make sure you're doing it for the right reasons, and not just because you can http://fsae.com/groupee_common/emoticons/icon_wink.gif

[Mike Sadie]

if you can find a manufacturer as Malcolm said, maybe see if you can have him teach you the process in exchange for work. What type of composites shop is letting you use their autoclave? Maybe they could help out.

[Garlic]

Is this for the upcoming Formula Student event in 2008?

If so, I would strongly suggest planning on building a 'standard' chassis for the coming event, whilst researching carbon and perhaps even building a 'test' tub during the year, looking to apply the technology in 2009.

Alternatively, you could use the autoclave to build smaller structural pieces for the 2008 car to learn the process.

[schmason]

the above points are very valid. you will also require the full support of your team to produce a carbon fibre chassis. the amount of manpower it takes to produce a carbon fibre chassis should not be underestimated