Forming a Ford logo car badge using a sheet of forged carbon fiber fabric, epoxy resin and a 3D printed mold.
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1:39 Dry forged carbon fabric is placed face down in a resin coated mold and additional resin added from the back to saturate. Attempting to add resin to the front of the sheet would break down the binder and cause the carbon pieces to dislodge/deform.
4:05 First casting was challenging to remove due to some slight undercuts in the mold and the very thin single layer part. It also had some gaps and thin spots which were filled and reinforced by adding small patches of additional carbon fiber to the back as shown at 5:40. The mold was revised for the second casting and a backing layer of twill weave carbon fiber added over the forged sheet, making the second part easy to remove and gap free.
5:48 This quick prototype mold was modeled in Fusion 360, 3D printed and minimally post-processed. Better designed and finished tooling would produce higher quality results straight from the mold.
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| Equipment Used |
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Lighting Kit: https://amzn.to/2DfaMiG

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