First Composite Parts

Hi all. Following the decision about putting on hold the engine testing, the modelling of the car is started. As a system check, I modelled this wing, following F1 standards. The CATIA model of the rear upper main plain has the intel for composite design of the part: ply pieces, splices, inserts, etc. The structure is quite complex and has Rohacell cores to reinforce the skins, plus two spars running across the wing span. The wing is 1:3 scale, meaning a total span of 252 mm. DXF are produced automatically to cut the plies on prepreg from the CAD model.

Material definition is now still to be defined both for part and tooling. This design and built exercise will prove the manufacturing cycle as well, since will use my Optimum BF20L vario to machine the patterns and final component. The CNC program will be made with Visual Mill based on the solid model created in Catia v5.

Time to move on

Even though the IT3 engine is not finished, I decided to put its development on hold. I have changed job and am living away from my home town, in where my workshop is. Hence, I will get started with the design of the car (chassis, composites). This means, there will be some uncertainties about the engine fitting into the whole, but I am sure I can get around it.

I expect the design to be finished somewhere around Oct - Nov 2013. The model and aero surfaces will be finished end of this year. The rest of the detail design will be finished afterwards, including the latest design of the 2013 cars. The particular car to be made will be determined next year, as the newer the car I chose the better it will look when finished in 2015-2016. The engine will be first designed and then the development will continue on the test bench, untill it is running well, recovering the IT3 work. Car manufacturing will start end 2013, along with the engine testing.

Follow me to learn more about the progress with the car design, which looks very exciting! A lot of composite parts to be designed and built! I will try to make some posts about composite manufacturing techniques as it is quite interesting for model making but actually just a few ones use it.