This page is a basic outlining of the forged carbon fiber pressure mold process as detailed in this video. This page will be expanded to include an operating procedure and example tests if time is allowed, as well as important things to keep in mind regarding the forged carbon manufacturing process.
This page leaves out much information regarding layup and general mold construction due to time constraints and the higher experience level of our current team in those areas. If more information is required on layup, the reader is suggested to look elsewhere.
Directly 3D-printed molds are best made out of PETG, with a high infill ratio of 70-100% to withstand pressures of the system.
A two part mold should have a draft of at least two degrees, to ease in disassembly of mold halves after curing. A three part mold can be near parallel, due to the easier separation process.
Bolt threading should be treated with wax to prevent resin lockup (filleting wax)
1.) Calculate volume of the negative mold section (values can be taken from cad or water displacement method)
2.) Calculate the weight of the finished composite piece. This can be done by multiplying your known volume by 1.4 $g/cm^3$
(the density of finished, cured forged carbon fiber) [1]
3.) Calculate the weight of carbon fiber strands needed to produce the part. For the forged carbon fiber process, this usually means a 60/40 ratio of carbon fiber strands to resin. Thus, take your total weight and multiply it by 0.6.
The calculation represented in equation form:
$Wtot = V * 1.40 * 0.60$