How to Build an Advanced Composite Clipboard

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1 How to Build an Advanced Composite Clipboard Tools and Equipment Measuring Tape Black Sharpie Silver Sharpie Rivet Puller Tile Saw or Hacksaw Drill and Drill Bits (5/32) Scissors Utility Knife Straight Edge or Angle Aluminum Cutting Surface T-handle nylon bagging tool Vacuum Source or Pump with Hi-temp hoses, vacuum gauge and Vacuum Probes Steel or Aluminum Caul Plates/tooling plates (18 x 24 ) Oven with Vacuum supply Safety Equipment (dust mask, Nitrile Gloves, safety glasses, and lab coat) Materials Tacky Tape / Sealant tape Flash Tape (1 ) Blue masking tape (1 ) Bagging Film (Rated for 300 +) Prepreg-Carbon/Graphite Fiber (Twill or Plain Weave) Unidirectional carbon Tape Peel-Ply Parting Film (Perforated and Nonperforated) Breather Cloth Class A Wipers MEK (Not Substitute) Frekote Mold release 2 Wax Free Mixing Cups 2 Stir Sticks Plastic Applicator/Sweep Sand paper (80 grit) 3M Scotch Bright pad Clear gloss spray paint Clip 2 Pop Rivets

2 Planning Kitting Keep the area that you are going to work in clean Read and follow all Material Safety Data Sheets Always wear safety gear/ppe when working with any resin systems or resin impregnated products (Resin contact with skin can cause irritation) Pre-preg Materials should be stored in a freezer in a sealed bag to prevent moisture contamination, but needs to be at room temperature for layup. Pre-Kitted projects require at least 15 minutes for thawing before working. An entire roll of Pre-preg requires at least 6 hours thawing time. Lay out materials on Cutting Surface Use Template part number CB-MEMO-R to mark out pieces to size. DO NOT USE TEMPLATE TO CUT OUT MATERIAL. Use Sharpie to mark shapes on the backing of the material Write Initials, ply orientation, and ply number in the center of each ply. Refer to Assembly drawing for ply Schedule and orientation. Pre-preg materials are expensive and careful consideration should be made to cut out pieces with minimum waste. Splicing Uni-tape is appropriate if necessary. Have another Mechanic Verify that you have the correct pieces marked out. Initial: Cut out material using Utility Knife and an Angle Edge. Write your name with a Marker on large letters on the Ply Schedule. Stack plies in order and seal inside bag with ply schedule on top. Place Kitted materials in Freezer for later date. Tool Prep You will need your aluminum caul plate. This will act as your tool. The caul plate will be placed on a level surface, preferably a worktable/bench. Remove any imperfections and contaminates with Scotch Bright pads. Scratches will affect the finish of the part. Thoroughly clean your caul plate with MEK (Methyl Ethyl Ketone). Caul Plate is Clean and free of deep scratches: (Mechanic Initial and Team leader or Instructor initial) Tape Blue Masking Tape around the perimeter of the caul plate.

3 Use a Class A contaminate free wipe to apply 1 of 3 thin layers of FreKote mold release to your caul plate. 1 - Move the wiper with steady even motion from Left to Right with no more than 50% overlap. 2 - Move the wiper from Top to Bottom with no more than 50% overlap. 3 - Move the wiper from Right to Left with no more than 50% overlap. Allow 10 minutes for the Frekote to flash between coats. Time of 1 st coat Time of 2 nd coat Time of 3 rd coat Continue ONLY after Team lead or Instructor Approval. Pre lay-up You must cut a piece of Peel-Ply that is 22" x 16". The pre-preg fabric will be 7W x 9". The non-perforated parting film also needs to be cut 22 x 16. Remove Blue Mask and place 2 rows of Tacky Tape in its place. (Leave paper on the tape) Place Masking Tape on the lower Center of the tool and draw a Rosette (Warp Clock) You must cut the breather cloth to cover the area inside of tacky tape. The bagging film must be cut to the size of your tool so that it extends over the tacky tape. Place the parting film on the inside of the tacky tape making it centered and taping it down with flash tape. Draw an outline on the parting film for the placement of the dry fabric and resin. You will place all of your materials on the tool the way it would be laid-up. By doing this you will know what order the material is going to be laid-up on top of the tool: Mold Release or Parting Film, Pre-preg fabric, Peel-ply, (Perforated parting film, bleeder), nonperforated parting film, Top caulplate (optional), breather, and bagging film. Continue ONLY after Team lead or Instructor Approval. Quick Tips Be sure to have all materials in order before lay-up. Have all vacuum hoses, vacuum probes, and vacuum pumps prepped and ready. Do a dry run to get a feel for how the lay-up will take place. Lay-up

4 WARNING Material must be thawed prior to exposing to ambient room temperature. WARNING Under No circumstances should material be placed in the oven to speed up the thawing process. *All frozen material must be brought up to room temperature prior to opening the material bag. Opening the bag exposes the material to ambient temperature. The reason for the specific thawing process is to eliminate the possibility of the material absorbing moisture due to the difference between the material and the surrounding air. Temporary bagging To ensure proper bonding and reduce possibilities of defects in our finished part you will need to make a temporary bag and apply vacuum for 1 minute to Debulk the plies. While there is no industry standard for this, it is recommended to temporary bag on your 1 st ply, every 3-5 plies afterward, and on the last ply. These circumstances may vary depending on the project. *Remember to use Parting Film between the Pre-preg plies and the breather material. Material Lay-Up Place a layer of Non-perforated Parting Film on the Tool. Secure the film with 4 x 2 strips of Flash Tape. Remove backing from Ply #1 and set to the side of tool. The backing paper will be stacked on order to confirm proper ply lay-up. Place Ply #1(Woven Carbon/Graphite) centered on the tool. If more than one part is being laid up on the tool, leave 2 gap in between each part. Leave enough space at the edge for a Probe to sit flat on opposite corners. Temporary Bag Remove paper backing on outside row only. Place parting film on Pre-preg, lay breather material, bag under vacuum for 1 minute. Then remove bag material and continue to next step. Place Plies #2-5 (Uni-directional carbon) one layer at a time. Stack backing paper in order. Temporary Bag Place parting film on Pre-preg, lay breather material, bag under vacuum for 1 minute. Then remove bag material and continue to next step. Place Plies #6-9 (Uni-directional carbon) one layer at a time. Stack backing paper in order. Place Ply #10 (Woven Carbon/Graphite). Stack backing paper in order.

5 Temporary Bag Place parting film on Pre-preg, lay breather material, bag under vacuum for 1 minute. Permanent/Final Vacuum Bagging Inspect and remove foreign matter and debris from the sealant tape and replace any damaged tape. Apply a 1 wide Edge Breather continuously around all sides of parts. Edge breather should be.75 inside of the Parting Film. Place Peel-Ply film on top of Pre-preg. Secure it tightly to the tool with Flash Tape Place Solid Parting Film on Tool. Secure Corners with Flash Tape Place one Layer of Breather material over the entire tool and should be within.5 from the sealant tape. Place two 4 x4 squares of Breather material as Probe Pads at opposite ends of the Tool. Place Probe bases onto pads. Secure with two small pieces of Flash tape. Starting from one side, remove the sealant tape backing and apply Vacuum bag film flat across the sealant tape. Without stretching the vacuum bag film, pull to opposite side and secure flat to the sealant tape. Remove the backing paper from long sections of sealant tape from between the Vacuum bag film. Use bagging tool to ensure proper seal Use a Utility Knife to cut a slit in the bag film in the center of each Probe Base

6 Attach the Probe Top to the Base with a ½ turn CW. Place a Vacuum Gauge on one Probe, and connect Vacuum hose to the other. When connected to a vacuum source, an acceptable reading of 25Hg/in - 29Hg/in at Sea-level. (Elevation will change this reading. Exp: at 10,000ft the max vacuum that could be pulled is 20.6Hg/in.) Record you reading: Hg/in Perform a Leak Down Test Pull full vacuum on the part and disconnect the vacuum source. You should not lose more than 2Hg/in within 5 Minutes. If it does, that part has a leak and needs to be fixed. Record your part vacuum loss over 5 minutes test Hg/in. If passed the part is ready to be cured on the Oven. Continue ONLY after Team lead or Instructor Approval. Place part on Staging Cart. DATE STAGED - - Clean up When cleaning up you do not want to throw away Pre-preg before it s cured. It is toxic to the environment when not cured. Leftover over small scraps can be placed in the garbage, and Pre-preg backing paper may be thrown out. Gloves may be thrown away and lab coats may but hung up. Extra hoses put away, Manifolds and Vacuum Gauges, and other tools put away.

7 Debagging Before debagging make sure that the resin has completely cured and the part is below 135 F. You do not want to debag your part before the cure time. Turn off the vacuum pump or disconnect from source. Pull the bagging film off the tacky tape. If it difficult to remove cut bagging film with scissors and take care not to damage the part or the tool. Peel back your breather, perforated parting film, bleeder, and non-perforated parting film. You're part should be ready for cutting, sanding, and drilling. WARNING - Carbon fibers and dusts are electrically conductive. Electrical equipment and machinery should be isolated to protect from damage. Cutting, sanding, and drilling When cutting the part you don't want to cut it without marking it. Use masking tape to cover the area where you are going to cut. Use a sharpie and Template CB-MEMO-F to mark the part where you want it to be cut. After marking your cuts you will cut your part with a Tile Saw, Band Saw with abrasive blade, or jigsaw. Once the part is cut you will sand (80 grit) and deburr the edges and corners of your part. You will also round the corners of your part. When sanding the part you want to get rid of the resin ridges, built up material, or any part defects. You do not want to sand to the point where you reach the ply's. After sanding the part you will paint on a clear coat to give it a glossy look. Before you drill the part, take the clip and clamp it at the top of the part and mark it. You can drill the holes with the-clip still clamped so that it is exact or you can remove the clip and drill the holes. Use a riveting puller to rivet the clip to the part. You will want to use clamps to hold the clip in place. Once your clip is riveted onto the part your clip board is read to be used.

8 NAME: Clipboard Ply Table Pre-Preg Ply # Material Orientation 1 Graphite 0 /90 2 Unidirectional Tape Unidirectional Tape Unidirectional Tape 0 5 Unidirectional Tape 90 6 Unidirectional Tape 0 7 Unidirectional Tape 90 8 Unidirectional Tape Unidirectional Tape Graphite 0 /90

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