Infusion of aerostructures: Doubling down on the

details
For this carbon-fiber composite manufacturer, little things make big differences in a notquite-new but still novel double-bag infusion technique.

Carbon Fiber Composites Inc. (CFC, Hurricane, W. Va.) molds this cowling for the Wittman Tailwind, a still popular plans-only
and at one time, all wood-and-fabric kit plane for which composite parts are now available. Source: Carbon Fiber
Composites Inc.

Step 1: The cowling mold is prepared with four coats of Sealer GP and four to six coats of Flex-Z 5.0 high-slip mold release,
both supplied by Zyvax Inc. (Ellijay, Ga.). Source: Carbon Fiber Composites Inc.

Step 2: Four layers of 6-oz plain-weave 3K carbon fiber fabric are cut and laid into the bottom, front and sides of the mold.
Source: Carbon Fiber Composites Inc.

Step 3: A peel ply is laid over the carbon fiber and taped to the flange of the mold. Note the use of two rows of tape for the
two bags. Source: Carbon Fiber Composites Inc.

Step 4: Two vacuum tubes are attached to the front of the mold. The main vacuum line is connected to a manifold that
permits the operator to alternate vacuum control between two different pumps, a dry pump capable of drawing 26 inches/Hg
of vacuum, and a wet pump capable of 29.5 inches/Hg of vacuum. A perimeter layer of CoreMat nonwoven polyester
functions as a breather and a dam to prevent resin being sucked out of the line before all the air is removed. Source: Carbon
Fiber Composites Inc.

Step 5: This view shows the light nylon mesh flow media that was laid over the peel ply to ensure smooth flow of the resin
into the laminate. Source: Carbon Fiber Composites Inc.

Step 6: The inner or first bag in place. Operators lay an excess of bag so that all the energy of the vacuum is being used to
compress the laminate. Source: Carbon Fiber Composites Inc.

Step 7: A vacuum of 29.5 inches/Hg is drawn with the wet pump and held on the inner bag for 45 minutes to degas and
compress the laminate. Source: Carbon Fiber Composites Inc.

Step 8: The second bag is taped in place and the mold is ready to be infused. During infusion operators hold about 20
inches/Hg of vacuum on the inner bag and about 29.5 inches/Hg of vacuum on the top bag. Source: Carbon Fiber Composites
Inc.

Step 9: After bags are leak checked, operators switch to the dry pump for the inner bag only and bleed pressure down to 20
inches/Hg while pulling 29.5 inches/Hg with the wet pump on the outer bag. Infusion is started and can be seen at the upper
right. Source: Carbon Fiber Composites Inc.

Step 10: The demolded part, shown here after trimming with a diamond wheel, is ready for shipment. Source: Carbon Fiber
Composites