Name:

Personal Innovation

Class Default Project

TEE 229: Fiber Glass/Carbon Fiber Lab

Warning: In this lab we will be using liquid resins and chemicals. These chemicals can be dangerous to your health. When handling the chemicals, wear chemical safety gloves. Do not directly inhale chemicals. Please follow all safety instructions.

Introduction:

Fiber glass and carbon fiber are two processes and materials commonly used in the automotive industry (think body parts of cars, boat hulls, etc.). The process often uses blow layups, however, traditional wet layups are still used – especially in prototyping.

Procedure

Step 1: Observe, list, and sketch 5 products that were created using a fiberglass or carbon fiber process.

1.

2.

3.

4.

5.

Step 2: Brainstorm and sketch a product you want to create using a wet-layup process. Innovative products will be given extra credit. Have the TA or professor sign off on the product, and provide the TA with a copy of your sketches. Note the product cannot be larger than 3’ x 2’. Or decide if you want to create the PRE-APPROVED/DEFAULT project: a small boat. Remember the “pre-approved” projects are “B” projects – meaning the highest grade you can receive if you select to do one of them is a B (based on completeness, execution, and cleanliness of project, and accuracy of lab write-up).

Step 3: You will use high density foam or light weight wood (i.e., balsa) or even high density cardboard to create a mold or skeleton of the product you wish to make (ex. A skateboard – has a foam interior and is covered in fiber glass). Use sanders, saws, glue, nails, etc. to create the mold/skeleton.

Step 3 – PRE-APPROVED/DEFAULT project: use some high density material to create a small boat (~6” x 2” x 4”). Use bandsaw (and other cutting tools) and sanders to create the hull of the boat.

Step 4: Identify the two compounds required for the wet layup. List the compounds and estimate the amount and consequent mixture ratios, and then apply a layer of the mixture using a paint brush. Then apply a layer of fiberglass or carbon fiber, and repeat as necessary:

Part A: (ratio: )

Part B: (ratio: )

Total weight:

Step 5: Sand and reapply layers as needed. A final paint job can be applied if desired.

Lab Write-up:

  1. What process parameters affect the part quality the most? Discuss 2 or 3 of these parameters and their specific effects on part quality. Which is the most important for cycle time?
  2. Your part has air bubbles, and excessive flash. What’s wrong, and how could you fix it? Give 2 parameter changes.

Design Problem:

Write a rapid lesson plan – outlining an idea for teaching and realistic project/activity a jr. high or high school technology and engineering classroom could do to learn and experience fiber glass or carbon fiber (needs to be distinctly different than what you did/we do in TEE 229). The lesson plan should include 5 parts: anticipatory set, what will be taught, activity, material, and evaluation (how the students will be graded).