Advanced Airfoil Construction Techniques
4 Days - 2 x Sat/Sun

The Boeing 787 structure consists of a carbon tube with carbon beams and carbon stiffeners. Of course this is dramatically over simplified but that is the theory of it. They do this because it is the current pinnacle of strength to weight ratio construction. In this 4 day course we teach you how to use this construction theory to build your own projects in your garage. You will create an airfoil using the mold you created in the previous class to build the skins, build a spar and place it for maximum strengthening of the airfoil longitudinally and assemble all components using techniques designed to prevent stress points when under load. This is the most advanced course we offer to date in the Compositech Foundations Series of courses. During this course you will apply all your skills to date and create a high performance airfoil using carbon skins and spars using basic processes you can recreate in your garage. 

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During this 4 day course you will:

• Learn the basics of specialized reinforcement fibres and weaves

  • Learn when to use specific reinforcement types (carbon fibre, kevlar, hybrids) based on load requirements

  • Learn basics of weaves, unidirectional and multiaxial reinforcement materials

  • Learn different reinforcement fibre weights and how you can use them to your advantage

  • Learn about cosmetic reinforcements such as hex carbon, colour carbon/ kevlar hybrids.

• Learn to plan and design structure of project

  • Learn what "spars" are and how they are used for strength and weight reduction within a composite structure such as a wing

  • Learn how to position structural members such as spars to maximize airfoil strength to deal with longitudinal stresses

  • Which laminates to use in which order, how many layers and best cosmetic results

  • What kind of internal supports are required to mount project

  • What materials to use for internal supports (mounting points) based on end results needs

  • Which laminates to use in which order, how many layers and best cosmetic results

  • Which matrix system (eg. Epoxy) to use based on end result needs

  • Which processes to assemble/bond components

  • How to add pressure (vacuum bagging) to the bonding process and what it accomplishes

  • Learn about elevated cure temperatures and when to use them (during cure or post cure)

• Learn how to prepare and use a mold to produce accurate products (mold from previous class)

  • How to clean a mold

  • How to apply mold release (wax and/or frekote)

  • How to prepare mold for vacuum bag

• Learn to apply laminates to mold with contour

  • How to place reinforcement fibres in mold and prevent movement

  • When to pre wet a mold

  • How to roll out plies once placed

  • When to impregnate plies, pre or post placement

• Apply pressure to composite airfoil structure using vacuum bagging

  • Learn special techniques for achieving best cured results​

  • Learn to work out air within vacuum bag

  • Learn to prevent and fix "bridging" problems in vacuum bag within mold

  • Learn advanced pressure tricks and advanced leak troubleshooting

• Learn assembly techniques for airfoil longevity and stregnth

  • Learn to plan assembly to prevent "hard points" or ridges where the airfoils can crack from load stresses

  • Introduction to specialty adhesives for carbon assemblies

• Learn trimming techniques specific to airfoils to repent damage to internal and external structure

  • Advanced trimming techniques for internal structure placement such as mounting points

  • Protection of finished composite structures when trimming to repent damage

• Use all of the knowledge and techniques above to create an advanced airfoil project that locks in foundational knowledge learned during course.

• Have fun through an open and fun learning environment in a home garage

• Have the required understanding and skills to move to the next step and further courses

• Certificate of completion

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Prerequisite: Introduction to Laminating and Intro to Vacuum Bagging

Basic safety equipment will be supplied such as: dust mask, safety glasses, disposable gloves. Must bring disposable painters coveralls/apron (chemical resistant).

Deposit: Non-refundable $100