From Core Airfoil  Techniques
2 Days - Sat/Sun

Learning new skills is great but using those skills is always better. During this course you will use the skills learned from the first two courses to build an airfoil with a foam core. Foam core construction is used in homebuilt aircraft such the "Quickie", a Burt Rutan design and many wings on completion race cars. This kind of structure is known as a "sandwich" structure (core material between composite laminates) and it makes for an exceptionally light & strong product. No matter what you're building, if you need high strength to weight ratio, sandwich structures are the way to get there when possible. In this course we will introduce the different types of core materials and how to work with them. Foam is quite possibly the most accessible and easiest of the core materials to work with. That is why we are using it for this project. You will learn to shape/prep the foam, laminate it with carbon fibre skins, vacuum bag the entire assembly, then trim and sand for final product. As you can see, there is a lot to cover so come to this class prepared to learn.

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During this 2 day weekend course you will:

• Learn the basics of core materials, their various differences and benefits

  • Different kinds of foam and their pro's and con's

  • Different types of wood cores and their pro's and con's

  • Different types of honeycomb cores and their pro's and con's

  • How to choose a core material for the end product and budget needed

• 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

  • Which core material and shape based on required end result​ needs

  • What kind of internal supports are required to mount project

  • What materials to use for internal supports 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 results needs

  • Which processes to assemble/bond components

  • Add pressure to bonding process or not (eg. vacuum bagging)

• Learn how to shape foam

  • Use a hot wire foam cutter

  • Use a rasp for shaping

  • Use various sanding block shapes for specific contours

  • How to fix foam when mistakes are made like sanding too much foam away

• Laminate carbon skins to foam core and supports

  • When to prepreg carbon reinforcement laminates​ or wet out in place

  • Learn how to work out air and tricks to remove inclusions/contaminates

• Apply pressure to composite airfoil structure using vacuum bagging

  • learn special techniques for achieving best cured results​

  • Learn to work out wrinkles and resin rich areas using decreased pressure/ roller techniques

• Learn trimming techniques specific to airfoils to repent damage to core.

  • Learn how to layout cut lines to prevent core damage​

  • Learn to template for securing final mounting points through carbon skins post cure.

• Use all of the knowledge and techniques above to create a fun foam core 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