fabricating a fiberglass shell chair
This process will assume that you have developed your own CAD file for the chair, but will take you through the process of making the form, pouring the glass fiber on the basis of this form, once the glass fiber is solidified, complete the processing of glass fiber. 1.
1 The 3D model must be made into a form in which fiberglass can be poured.
To do this, I flipped my shell shape so the seat was down and the Edge (
Flat on the x plane.
Then I made it into an entity.
Filling in the seat cavity).
The results are shown in the figure. 1.
The model must then be divided into several parts.
Every 1 piece of my model.
8 inch, the thickness of the 4ft × 8ft Polystyrene Sheet I used.
Other materials can be used, but keep in mind that the thinner your material, the more time you need to increase the thickness, the more time you need to cut all these parts. 1.
3 these slices can be arranged into a 4 ft x 8 ft boundary suitable for each piece of material (
Depending on the size of your chair, multiple sheets may be required).
Laying these parts on 4ft x 8ft paper can help you understand how many pieces of material are needed to make the form.
I then export the file as. STL file. Once my tools.
Stl files are sliced and laid out to fit the area of 4 ft x 8 ft paper.
I can easily see that I need 5 1.
4 ft x 8 ft thick polystyrene.
Next, you need to import this file into CAM software.
I use rhino.
If you try to cut
The download attachment for the dense foam \'feeds & Speeds \'is included.
This file has some suggested settings for cutting various materials that will be used with most 4ft x 8ft Mills.
Make sure to add labels to CAM software (
This is an option in most tools)
Because this will keep the position of the debris at the time of cutting. 4.
1 Make sure the CNC is up and running (
Consult your store supervisor to make sure everything is OK). 4.
2 put polystyrene on the CNC bed. 4.
3 Make sure to use some double sided tape between the material and the grinding machine tool to prevent the foam from moving around when cutting the file. 4.
If you are CNC, you want to turn on the vacuum cleaner now. 4.
Next, you want to load the first cut file (
You need to cut one page of material at a time). 4.
Repeat until all slices are cut out.
If your cam software doesn\'t tag your slice, you might want to take a tag and tag each piece so it\'s easier to remember what\'s behind.
Now that everything has been cut off, you\'ll want to collect all the processed foam layers and place them in a predetermined order.
This can be tricky if you have a lot of sections, but if you mark them as per the previous steps, the numbers will help guide you.
I chose to connect my part using 3 \"drywall screws and fasteners, but you can also use 3 m polystyrene foam insulation 78 spray glue.
In my experience, this can be eaten on polystyrene.
You can sometimes limit this effect by spraying the adhesive from a further distance.
Any method should be strong enough for our purposes.
One part should be added each time to ensure that the part does not shift when the glue is dry or screws are added.
Tools and materials needed: now you want to cover the template with plaster.
This will seal the foam and enable the fiberglass parts to be removed smoothly at a later date. 6.
1 apply a uniform plaster coating on the tool to make the plaster completely dry between the coatings. 6.
2 Make sure the coat is completely evenly covered on the plaster and can brush points if you miss anything. 6.
After applying all the necessary plaster and having time to dry it.
Apply the Minwax finish wax tool and a single coating of the required material: the following steps will help ensure that the fiberglass chair case is released from the template. 7.
1 brush the template with a layer of paint, allowing for complete drying. 7.
Brush the template with three layers of PVA, before applying the next layer, be sure to make each layer completely dry.
Technology: wet shop-up \'pre-preg\': \"[Fiber glass]
A mat made of woven reinforcement material that is soaked in resin between fibers.
The amount of resin is accurate so that each layer of lamination can provide the best performance.
This reduces the weight and increases the strength of the product \"(
Manufacturing process for design professionals by Rob Thompson)
Tools and materials required: synthetic fiberglass veilFiberglass roll mixing container
The density white plaster dry mix begins by covering the template with a synthetic fiberglass veil.
The synthetic fiberglass veil will cover the top and bottom layers to minimize the need for sanding in later production.
Mixing epoxy resin with hardening agent (
Ratio and mixing time can usually be found on the package).
Pour the mixture onto the template covered by the veil.
Evenly spread the epoxy resin with a fiberglass drum.
Fiberglass should now be saturated evenly with epoxy. 11.
1 paving plate 1. 5 oz.
Shredded stock pad fiberglass at the top of the template and use the roller to drop them down. Repeat11.
2 apply epoxy.
Repeat these steps until the required shell thickness is reached.
Done by covering the template with a synthetic fiberglass veil to minimize the need for sanding in later production.
It is important to allow the total time described on the resin curing package.
After the fiberglass is cured, you should be able to pop up the shell from the template.
In order to smooth the edges and surfaces of the shell, some sanding may be required.
At this point, you will complete the manufacture of your shell.
If your design does not have integrated legs, you can either connect a set of ready-made legs or build it yourself.