Bike Tire Pry - Forged Carbon Fiber

Overview This is a mold set for making a forged carbon fiber bike tire pry/lever. This is a 3 part mold consisting of two core sections and a single cavity section. This helps in releasing the part from the molds. NOTE: This is not intended to be a comprehensive guide to forged carbon fiber with 3D printed molds. Tutorial: (general forged carbon fiber) Below is a link to some how to videos on forged carbon fiber. These videos from easy composites are great guides for the process as well as provides comprehensive list of materials needed for making your own forged carbon fiber parts. Once you get your process dialed in you can make remarkably strong and detailed parts using this method.

Things to consider FDM Molds: - Materials: Recommend using PETG for molds. It is easy to print, provides a relatively smooth surface for release, and it is readily available and cheap. Other materials can certainly be used, including PLA, but if you are heating your mold or expect heat to be generated by the curing process PLA may not be the best bet. It is not uncommon for FDM printed molds to become damaged and unusable after a single mold process.

- Infill: high infill of 80-100% is recommended for the molds or you will likely have mold failures due to the very high pressures that build up when pressing the molds. You can get bulging in locations or complete mold failure. Alternatively, you can go with a very low infill and no bottom layers on the print and pour resin into the mold as the filler.

- Post Processing: Depending on layer heigh, print quality, etc. you may want to lightly sand any rougher regions of the mold to improve part release and surface finish.

Resin Molds: - Materials: I have used several resins with success. Siraya tech sculpt grey is a good option. I also like any of the Phrozen aqua series resins.

- Post Processing: Resin molds can be tricky if you do not fully clean and cure the resin printed parts prior to prepping with mold release. If the molds are not fully cleaned of any residue or under-cured resin this can result in permanent adhesion of the forged carbon fiber part to the molds.

Materials/Tools Needed Forged carbon fiber materials/tools - All-in-one kit: https://www.easycomposites.us/forged-carbon-fiber-kit

OR - Chopped carbon fiber: https://www.easycomposites.us/virgin-chopped-carbon-fiber-tow

- Resin (low viscosity): https://www.easycomposites.us/in2-epoxy-infusion-resin

- Mold release: https://www.easycomposites.us/rw4-spray-wax-release-agent

- Paint brushes for stippling resin in with carbon fiber: https://www.harborfreight.com/12-in-horsehair-bristle-acid-shop-brushes-36-pack-61880.html

- Tools for laying down chopped fiber: https://www.easycomposites.us/prepreg-laminating-dibber-tools popsicle sticks, silicone scrapers, and decal applicator tools work well too

Hardware/Other - M3x30mm socket head cap screws: https://www.mcmaster.com/91290A171/

- M3 hex nuts: https://www.mcmaster.com/90591A250/

- Vise or Clamps: Any typical vise (even wood vise) or C-clamps will work well for this smaller mold.

- Parchment paper: This can be used between the vice or clamps and the mold as well as to catch excess resin as it is pressed from the molds.

Part Composition - Chopped Fiber Mass: 9.4 grams

- Resin Volume: 5.6mL

NOTE: I always mix up a bit extra resin, especially since this is such a small volume. That way if you end up feeling like you need more to fully wet the chopped carbon fibers you will have it ready to go. Additional Notes/Comments - I highly recommend the RW4 mold release linked above. I have tried lots of other mold releases, with varying success, and can say that this has worked by far the best with 3D printed molds.

- Most relatively low viscosity resins will work well. I have used the one linked above as well as others with positive results.

- If using C-clamps I recommend using wood boards or some solid plates between the clamps and the mold sections.

- Be careful to slowly clamp the molds together to avoid damage to the molds and failed parts.

- The Zyliss Swiss Made 4-in-1 Bench Vise Clamp System is a cool vise if you can find one, but not suitable for larger molds.