Uploaded November 2022 | Updated September 2026, 1 week ago
Shop products (USA) ►easycomposites.us/learning/moldless-carbon-fiber-aero-wing
Shop products (EU) ►https://www.easycomposites.eu/learning/mouldless-carbon-fibre-aero-wing
Shop products (UK & World) ►easycomposites.co.uk/learning/mouldless-carbon-fibre-aero-wing
Further information and links ▼
In this step-by-step video tutorial we demonstrate a method of making high performance carbon fibre downforce/aero wings for motorsport without needing a mould. Instead, carbon fibre is laminated onto the outside of an XPS foam core which has been profiled using a hotwire cutter. Mylar is used to smooth the carbon fibre and a vacuum bag is used for consolidation. End plates, which include aluminium mounting inserts, are made using Nomex honeycomb bonded to carbon fibre sheet.
00:00 - Introduction
01:37 - Hotwire cutting XPS foam core
04:05 - Machining wing inserts
05:21 - Cutting Mylar surface film
06:14 - Prepare the vacuum bag
06:31 - Preparing the carbon reinforcement
07:33 - Wet-out reinforcement with epoxy
09:18 - Wrapping the carbon fibre around the foam core
11:22 - Machining the carbon sheet for the end plates
13:06 - Aluminium inserts for the end plates
14:56 - Cutting and bonding Nomex honeycomb
18:09 - Filling the edge of the honeycomb panel
18:36 - Assembling the finished wing
For further information, including links to all products used in the tutorial, see the tutorial's project page on the Easy Composites website:
Full Project Details
USA ►easycomposites.us/learning/moldless-carbon-fiber-aero-wing
EU ►https://www.easycomposites.eu/learning/mouldless-carbon-fibre-aero-wing
UK & World ►easycomposites.co.uk/learning/mouldless-carbon-fibre-aero-wing
Shop products (USA) ►easycomposites.us/learning/moldless-carbon-fiber-aero-wing
Shop products (EU) ►https://www.easycomposites.eu/learning/mouldless-carbon-fibre-aero-wing
Shop products (UK & World) ►easycomposites.co.uk/learning/mouldless-carbon-fibre-aero-wing
Further information and links ▼
In this step-by-step video tutorial we demonstrate a method of making high performance carbon fibre downforce/aero wings for motorsport without needing a mould. Instead, carbon fibre is laminated onto the outside of an XPS foam core which has been profiled using a hotwire cutter. Mylar is used to smooth the carbon fibre and a vacuum bag is used for consolidation. End plates, which include aluminium mounting inserts, are made using Nomex honeycomb bonded to carbon fibre sheet.
00:00 - Introduction
01:37 - Hotwire cutting XPS foam core
04:05 - Machining wing inserts
05:21 - Cutting Mylar surface film
06:14 - Prepare the vacuum bag
06:31 - Preparing the carbon reinforcement
07:33 - Wet-out reinforcement with epoxy
09:18 - Wrapping the carbon fibre around the foam core
11:22 - Machining the carbon sheet for the end plates
13:06 - Aluminium inserts for the end plates
14:56 - Cutting and bonding Nomex honeycomb
18:09 - Filling the edge of the honeycomb panel
18:36 - Assembling the finished wing
For further information, including links to all products used in the tutorial, see the tutorial's project page on the Easy Composites website:
Full Project Details
USA ►easycomposites.us/learning/moldless-carbon-fiber-aero-wing
EU ►https://www.easycomposites.eu/learning/mouldless-carbon-fibre-aero-wing
UK & World ►easycomposites.co.uk/learning/mouldless-carbon-fibre-aero-wing
