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A composite material is a material system

composed of two or more macro constituents

that differ in shape and chemical compositionand which are insoluble in each other. The

history of composite materials dates back to

early 20th century. In 1940, fiber glass was first

used to reinforce epoxy.

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Hand Laminating with prepreg

Cutting Master Patterns

Patterns prepared for Moulding

Composite curing assembly

Chasis assembly

Flow chart of the fabrication process

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• Stacking of oriented layers of oriented prepreg

• Parameters that need to consider ply thickness, fibre type, ply

orientation and matrix materials and plies of the F1 team

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• Full needed size pattern are cut accordingly

based on setting of CAD system.

• The body are cut used 5 axis CNC millingmachine.

• Patterns are cut from a tooling block

material(generally contain solid epoxy resin

containing glass micro spheres)

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  After MouldBefore Mould

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• Curing using the technique of internal pressure bag

• Pressure bag applying vacuum

• Additional pressure applied through elastomer bag

• The bag open to autoclave glass ensuring isostatic pressure applied to mould

parts

• Curing take place 7 bar pressure for 1-2 hours

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Manufacturing carbon fiber can have serious environmental ramifications

and pose immediate danger to humans.

HCN & NH3

Immediately

dangerous to

human health insmall quantities.

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Characteristics of materials

Super light weight

Super Strong

Super Stiff

Easily moulded into different shape

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Mechanical properties

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Example of usage

This carbon fibre safety cell is virtually indestructible and plays a key role in

the safety of Formula 1.

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References • Lin Liao, Journal of Advanced Materials, 1998, 30(4), 3-40.

• G.Pritchard, Reinforced Plastics Durability, Woodhead, 1999.

• Sehanobish, K, A Vision for Carbon Fiber Composites (CFC) inAutomotive, 2009,9th Annual SPE ACCE Keynote Presentations,(2009)

• Song,Y., Youn,J., Gutowski,T., Life cycle energy analysis of fiber-

reinforced composites. Composites, Part A 40 (2009) p. 1257

• Verpoest I, Thanh TC, Lomov S (2005) The TECABS Project:Development of Manufacturing, Simulation and DesignTechnologies for a Carbon Fibre Composite Car. Proceedings of the9th Japan International SAMPE Symposium, 56 –61.

• G. Savage, Composite material technology in formula 1 racingcar(2008)

• http://www.f1scarlet.com/f1_beginners.html#construction

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