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Composite Design and Manufacturing 03: Validation and Production

Composite Design and Manufacturing 03: Validation and Production

1h 11mBeginner2021-06-09

Authors

Aram Goganian

Aram Goganian

Founder, Lead Designer, and Engineer for Predator Cycling

Course details

In this three-part Composite Design and Manufacturing series, carbon fiber product designer and fabricator Aram Goganian presents an essential guide on composite design and manufacturing, detailing the building of an actual consumer product—in this case a balance bike—from composite design to the finished product. This third course in the series presents the final design workflow management and the integration of supplemental component additions that affect the end-product production plan. Aram shows how to use tools like CFD solvers to finalize the wind flow to make sure that the part is designed correctly, and how to use composite simulation tools to make sure that the parts are laid up correctly and structurally sound. He finishes the course by showing how to make the mold, produce and test the parts, and get the product out the door.

Skills covered

Fusion 360Product and Industrial DesignAutodeskProduct and ManufacturingDeep Dive (X:Y)

Concepts

0. Introduction

  • 01 - Build better with composites
  • 02 - Preparation of carbon fiber material and components parts for manufacturing

1. Adding Model Details

  • 03 - Understanding bearing races in a composite object
  • 04 - Threaded holes for precision inserts
  • 05 - Integrating prebuilt components into composite structures

2. Simulating and Creating a Composite Structure

  • 06 - Software validation and simulation of CFD data
  • 07 - Set up CFD
  • 08 - CFD testing
  • 09 - Set up a model to build layup
  • 10 - Build layups
  • 11 - Simulate composite layup
  • 12 - Flatten layup for cutting

3. Composite Mold

  • 13 - Mold design overview
  • 14 - Design mold
  • 15 - Mold CAM (computer-aided manufacturing)
  • 16 - CAM to CNC (computer numerical control) in composite cutting

4. MFG of Children's Composite Carbon Fiber Push-Bike

  • 17 - Laying up part with mold and core
  • 18 - Curing part and removing part

5. Testing Validation

  • 19 - Calibrating testing of push-bike
  • 20 - Reviewing data from MFG and comparing with simulations
  • 21 - IoT data from MFG process

Conclusion

  • 22 - Go ride

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