Molding Ford Emblem with Forged Carbon Fiber Fabric 

I like your project, an I can share some of my own experience. First of all, the result is way better then I anticipated. I expected the lettering to be filled with resin from the resin coating, but you managed to keep this to a minimum. I have also laminated onto 3D-Printed molds before, and figured out some tricks that make your life much easier. First trick is to not rely on vaccum alone to ensure the pressure into the mold. Vacuum is great for bigger parts, as it ensures an even and normal force destribution, pressing the part into the mold. The smaller the surface becomes however, the more pronounced other factors become. On tight bends / edges and especially corners, the fibers tendency to lay flat show in a distinct and pronounced way. It usually shows up as blobs of resin and bridged fibers and it predominatly happens in normal weave laminates. Forged laminated can mitigate some of these problems by having shorter fibers, but not all of them. How you you get around the problem of bridging? You need to realize that any flat material has a tendency to bridge. the thinner the flat material, the lesser it does so. The first step is to go for more layers of thinner materials. Instead of 1 layer of 12 k Carbon, you can go for 4 layers of 3 k Carbon. The release nylon bridges as well - I've circumvented this by using small flakes (2 x 2 cm fabric insted of one huge weave) on my parts. Lastly, the vacuum bag itself can also bridge, so choosing a thinner bag can help a lot (but also carry the risk of it rupturing on sharp edges massively, so take good care). In case all of these tips still don't leave you with a satisfying result, you can take it to the next step. Instead of trying to force some flat material to conform to the mold, you can preform the background material beforehand. I've tried both printing a postive and negative mold and sandwhiching the carbon inbetween using vaccum and using a deep drawn plastic backplate from the same mold. Both work well, while the 3D printed positive yields the best results. In case you are interested in more information on my experience with these methods, including pictures of the processes, you can e-mail me under f.hilken@fasttube.de Great project, keep it up!

Lindy I love the fact your dedication is amazing! Try this out take the extra cut off fabric chop it up with scissors into pieces. Since your using forged carbon there's no particular direction of the weeve. Use a small 1 or 1/2 inch chop brush to apply resin and chopped up mat into the detailed areas. Use just enough resin for fibers to stick. I like to wait around 15 minutes resin will become sticky before starting to apply fibers. Use your chop brush to wet out the fibers once they are set into place along with the rest of the part. After doing those steps than apply the forged fiber mat on the part and vacuum bag. NOTE: preparation of the mold is 98% of the job. Sand down the mold with 1500 grit , Use tooling gel coat ( for molds) much less sanding will be required after releasing part.

Great vid and product links, this is the first I've seen of forged carbon fibre and it looks great, thank you

well done i love the whole learning process you went through very cool , and the 3d printed mould loooks awesome

Nice Video. When I used to work at CA Models I used a Stratasys 3dprinting machine to build many exhaust manifolds in dis-solvable support material. Very interesting method.

Another nice work, Lindy! Of a good car brand! Together with faithful Toyota, btw... Thanks once again! Cheers from Argentina!

Awesome video. I really want a set of Audi rings for my car like this. That would look sick on my new build.

wow that's amazing how that has come up bet there will be a few who would want to buy that

As a ford guy that makes carbon parts, I like this.

Nice work Lindy!

I really like the result. It looks really nice.

Great video. So nice/lovely work you do. I like/love your videos.

neat, thank you for sharing

I’ve found you can make a carbon water slurry put it into a form then dry or evaporate the water out of it, it retains the form but is dry. At this point you can draw resin into it. This has the advantage that it flows well and is as dense as you desire

On a cosmetic finish part you need to use more resin during the lay up process. More time forcing the fabric into the tight corners and details of the mold.

Obviusly vacuum infusion get you better result. here my advice about relise - wax&PVA is not best chose for mould relise, use the Loctite 770 nc. To fix carbon cloth in mould use the 3m 77 spray adhesive - it good fixes cloth in the mould and dissolve by injected resin. About resin for injection - good choice is Biresin LS or analog whith same specifications, or resin with fast curing time, for your small parts. I hope my advice will help you in your projects.

Perfect 👌🏼

thats so cool

I need 2 of these

Cool video, cool channel. Keep up the good work.

Grazie fantastico !!!!

I would love to do try to this on automotive interior trim panels/pieces. Any idea how much thickness it would? I am wondering about fitment issues

Awesome.

It would look awesome on my grill

high level

The emotional story told by the music as well as the pacing in the edit are very very nice. I think you took just as great care in your video production as you did with your carbon project. It feels so well put together, pleasant to watch and easy to understand.

Great video. You should do a Raptor Claw from Jurassic Park!

Nice Video. where you get the Blue Stick to sealer the bag?

*Nice!*

I need 2

Who is that lucky chap who will send me that mould ??

Love it! I have 20 ford vehicles right now.... Do I have a ford fetishist or am I a ford horder?

Darker on finished product, i had the same issue with twill carbon, is that normal?

You know you're watching a Lindy video when she has a pretty good looking finished product but the video is only half done because she's going to do it all over again because she knows she can do better. :P

Any way to buy a set from you for 2019 f15p

Very cool. A Chevy emblem would have turned out much better though.

Should've colored the Ford before clear coating

Where can I buy this for my Ford and how much

I wish i had your skill. There is a few things i want to make with carbon fiber but it won't turn out as good 😔

Can you make a bmw badge? Or how do you make it

Do you sell something like this? I would like to have 2 for my focus mk3.

is there a link to the mold stl ?

The “forged” style fabrics from Ulticarbon are SUPER expensive for the amount that you get. I’m used to paying $30-$40 per 36”x50” piece of carbon fabric. They want $168 for a 24”x36” piece of the standard finish??! Hell no. Has anybody tried to make their own “forged” style cloth for easier mould layups?

Do you sell those 3d printed molds?

So when u gonna mail that to me? lol

Great work. You made Elon Musk crying again.

You would get a nicer end product if you made a mold(fiberglass and gel coat, etc.) from a real Ford emblem/badge rather than using that roughed out 3d printed mold. Still looks pretty decent though, nice work.

それじゃフォードも納得しないだろうな

It requires a lot of work, no thanks

Whilst I admire you doing it yourself, use laminating brushes for the resin. I'm not sure why you use sticks and your fingers!

Cool project but no warning about sanding CF? Safest way is submerged or under running water, if you are going to sand it in open air make sure your mask can filter it out... so no regular dust mask from a bigbox store, be safe they're the only lungs you got😜

งานโคตรหยาบ555

I doesn’t look that good

Forged carbon looks like ass compared to the real thing.

omfg is that bad sry

Failed in so many levels. Good try still.

you are working too hard but result is always bad :(

Not worth the effort looks sus. No detail or clearly defined lines and edges.

Brother your diy is not good