How We Manufactured the Carbon Fiber Wing for Dark Arrow One

🛠️Manufacturing carbon fiber structures is challenging due to the difficulty of mass production and automation.

👨‍💼Designing for manufacturability is crucial to ensure that a composite structure can be built without encountering roadblocks.

📏CAD modeling and CNC cutting are integral to shaping the carbon fiber parts accurately.

🔧Creating molds using CNC routing and polyurethane tooling board allows for the production of accurate and robust molds.

🌬️The infusion process, using vacuum bagging and epoxy resin, is employed to combine the carbon fiber and resin to form the final part.

Why is manufacturing carbon fiber structures challenging?

—Carbon fiber structures are challenging to manufacture due to the difficulty of mass production and automation.

Why is designing for manufacturability important in composite structures?

—Designing for manufacturability ensures that a composite structure can be built without encountering roadblocks during the manufacturing process.

What role does CAD modeling play in the manufacturing process?

—CAD modeling allows for accurate shaping of carbon fiber parts, which is crucial for manufacturing composite structures.

How are molds created for the manufacturing process?

—Molds are created using CNC routing and polyurethane tooling board, resulting in accurate and robust molds.

What is the infusion process in manufacturing carbon fiber parts?

—The infusion process combines carbon fiber and resin using vacuum bagging and epoxy resin to form the final part.

00:00Introduction to the challenges of manufacturing carbon fiber structures and the focus of this video.

01:00Importance of designing for manufacturability from the beginning of the design process.

02:00CAD modeling and CNC cutting are utilized for shaping carbon fiber parts accurately.

04:00Creation of molds using CNC routing and polyurethane tooling board for accurate and robust molds.

07:00Explanation of the infusion process, combining carbon fiber and resin using vacuum bagging and epoxy resin.