Exploring CFRP manufacturing processes using 3D-printed moulds — an approach that combines the design freedom of 3D printing with the mechanical properties of carbon fibre.

Process

Two different processes were explored: classic wet layup with a single-sided mould, and forged carbon — a compression …

Built during the design internship of my apprenticeship at Empa — and at the same time a first deep dive into professional CAD design with Catia.

Design

All components were modelled true-to-scale in CAD, forming the basis for a flyable frame for an FPV racing quadcopter. The frame parts were …

A classic cockpit upgrade: a replica of a trim lever — from material fabrication to surface coating of the finished part. First, a CFRP plate is laminated, the lever is CNC-milled from it, a brass insert is bonded in, and finally the part is coated.