Production of carbon parts by vacuum infusion is a painstaking and multi-stage process. It begins with the manufacture of the matrix. Flanges (additional technological part) are added to the standard part or the modified element. Slits, windows and openings are insulated with sculptural plasticine to ensure that the matrix is intact. The prepared element is covered with a separator to be able to remove this element from the future matrix. In 1-2 layers then apply a matrix gelcoat (taking into account the temperature in which the matrix will be used). After complete drying, the gelcoat is ground with sandpaper for better adhesion with subsequent layers. After that, the resin is gradually applied in several layers and reinforced with fiberglass. To avoid deformation, the matrix is reinforced with metal angles or profile.
Then the matrix is prepared for carbon insertion. It should be noted that the better the matrix is made and prepared – the better the future part will be. You need to remove scratches (if any), imperfections, dents, give a matrix of gloss and apply a separator.
Carbon is prepared with the help of patterns. Depending on the complexity of the part and the inspection of the visible parts, element by element, the blanks are inserted to ensure integrity, so that the effect of “one piece” is visually observed. For strength of the future part add the following layers and reinforcements in the places of fastenings.
In order to impregnate the carbon with resin with hardener, a technical fabric (sacrificial fabric – peel ply, and a conductive fabric for resin flow) is applied to the carbon layers. Eventually, after “spilling”, these fabrics will be separated from the part, as their purpose is fulfilled.
So, in fact, vacuum infusion is the process of infusing resin into a vacuum medium. To do this, spiral tubes, resin supply tubes and air intake tubes are laid out along the technical part of the matrix (flanges). An insulating tape is glued to the vacuum film prepared according to the dimensions of the matrix and placed on the matrix, again, on the technical part. The air intake tube is connected to the vacuum pump, it will leave the part without air and press the film to the conductive fabric, so, accordingly, the future part will be formed. The other end of the resin supply tube is immersed in a container with resin. The pump will replace the remaining air in the thickness of the part with resin. Tightness should be monitored until the part hardens. The matrix should be heated to ensure a stable chemical process of the laminate and post-curing. This process takes, depending on the resin and hardener used, from a few hours to 2 days.
As mentioned above, technical fabrics are detached from the part. The finished part is processed by removing the flanges and adjusted to the car or a single element. In the case when the part is technologically complex and consists of several separate parts, and accordingly the matrices, after the process of infusion and fitting, the gluing process takes place. The laminate itself is not resistant to sunlight and precipitation, so the details are protected by transparent acrylic and polyurethane gelcoats and varnishes. Therefore, before the next process, the part is cleaned of glue residues and dried. After polishing the lacquer coating, the part is installed on the car and it can please its owner.