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PRO CASE STUDY

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
OV301 Precision Composites Curing Oven Thumbnail
OV301OV301 Precision Composites Curing Oven£1914.00 /each

VC200 Quick-Release Vacuum Coupling Set Thumbnail
AFVC200VC200 Quick-Release Vacuum Coupling Set£14.34 /set

TBC2 Through-Bag Connector Thumbnail
VBTBC2TBC2 Through-Bag Connector£19.80 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£276.00 /each

Total £0.00
COMPONENT MATERIALS
XC110 210g 2x2 Twill 3k Prepreg Carbon Fibre (1250mm) 2m Roll Thumbnail
XC110-C331T2-210(1250)-2XC110 210g 2x2 Twill 3k Prepreg Carbon Fibre (1250mm) 2m Roll£118.01 /roll

XC130 300g Unidirectional Prepreg Carbon Fibre (300mm) 10m Roll Thumbnail
XC130-C2412UD-300(300)-10XC130 300g Unidirectional Prepreg Carbon Fibre (300mm) 10m Roll£108.96 /roll

Total £0.00
PATTERN MAKING MATERIALS
S120 Advanced Board & Mould Sealer 250ml with Nozzle Thumbnail
S120-025S120 Advanced Board & Mould Sealer 250ml with Nozzle£63.54 /pack

EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 1500mm Thumbnail
EB700-075-100EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 1500mm£545.40 /block

Total £0.00
MOULD MAKING MATERIALS
XT135/B 415g 12k Tooling Prepreg Carbon (1250mm) 10m Roll Thumbnail
XT135B-C1212T2-415(1250)-10XT135/B 415g 12k Tooling Prepreg Carbon (1250mm) 10m Roll£745.20 /roll

XT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 2m Roll Thumbnail
XT135S-C311T2-250(1250)-2mXT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 2m Roll£153.34 /roll

Total £0.00
MATERIALS & CONSUMABLES
Easy-Lease Chemical Release Agent 1L Thumbnail
ELRA-1Easy-Lease Chemical Release Agent 1L£28.50 /pack

VBT155 Self-releasing Tubular Bagging Film - 150mm - Linear Metres Thumbnail
AFVB155-015LFTVBT155 Self-releasing Tubular Bagging Film - 150mm - Linear Metres£1.36 /linear metre

BR180 Breather Cloth (1520mm) Linear Metres Thumbnail
AFBR180-152BR180 Breather Cloth (1520mm) Linear Metres£1.98 /linear metre

R120 P3 Perforated Release Film (1500mm) Linear Metres Thumbnail
AFR120-P3-150R120 P3 Perforated Release Film (1500mm) Linear Metres£0.90 /linear metre

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£5.99 /roll

VB160 Vacuum Bagging Film LFT (1520mm) Linear Metres Thumbnail
AFVB160-152LFTVB160 Vacuum Bagging Film LFT (1520mm) Linear Metres£2.40 /linear metre

Total £0.00

PRO CASE STUDY

SEQUENCE Carbon Fibre Downhill Bike

The design and manufacture of leading edge carbon fibre MTB frames is normally the reserve of established companies with a large team of engineers and an even larger budget, independent design engineer Vladimir Yordanov chose to challenge this by fulfilling his long ambition to design and produce a batch of his own downhill mountain bikes.

As with most composite projects the first hurdle was the mould. Typically, in volume production, mould tools for a bicycle frame would be machined from billet aluminium, however this was prohibitively expensive for this project so, with our recommendation, Vlad decided that creating composite tooling from epoxy model-board would provide moulds that were perfectly accurate and sufficiently durable for smaller batch production at a fraction of the cost.

The pattern was CNC machined from epoxy model board using a 3-axis router and moulds were then produced from the XPREG XT135 prepreg tooling system. Which made strong, precise and temperature stable tooling for the bike. The frame itself was laminated with XPREG XC series prepregs making extensive use of unidirectional reinforcement to optimise the laminate and match the anticipated loads. The curing of both the mould and the frame was done out-of-autoclave in the ECP OV301 benchtop curing oven.

Except for some aluminium frame inserts every part of this project was completed with materials and equipment supplied by easy composites. If you want to learn more about this project, we have an in-depth article on the build in our learning area. Click here to view the full project.


SEQUENCE DH BIKE SPECIFICATION

ConstructionXPREG® prepreg laminate.
Travel200mm
Wheelbase1250mm
Wheel Size27.5"
Head Angle62.5º (adjustable)

ABOUT VLAD YORDINOV


USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
OV301 Precision Composites Curing Oven Thumbnail
OV301OV301 Precision Composites Curing Oven£1914.00 /each

VC200 Quick-Release Vacuum Coupling Set Thumbnail
AFVC200VC200 Quick-Release Vacuum Coupling Set£14.34 /set

TBC2 Through-Bag Connector Thumbnail
VBTBC2TBC2 Through-Bag Connector£19.80 /each

EC.4 Compact Composites Vacuum Pump + UK Lead Thumbnail
VP-EC4-UKEC.4 Compact Composites Vacuum Pump + UK Lead£276.00 /each

Total £0.00
COMPONENT MATERIALS
XC110 210g 2x2 Twill 3k Prepreg Carbon Fibre (1250mm) 2m Roll Thumbnail
XC110-C331T2-210(1250)-2XC110 210g 2x2 Twill 3k Prepreg Carbon Fibre (1250mm) 2m Roll£118.01 /roll

XC130 300g Unidirectional Prepreg Carbon Fibre (300mm) 10m Roll Thumbnail
XC130-C2412UD-300(300)-10XC130 300g Unidirectional Prepreg Carbon Fibre (300mm) 10m Roll£108.96 /roll

Total £0.00
PATTERN MAKING MATERIALS
S120 Advanced Board & Mould Sealer 250ml with Nozzle Thumbnail
S120-025S120 Advanced Board & Mould Sealer 250ml with Nozzle£63.54 /pack

EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 1500mm Thumbnail
EB700-075-100EP700 High Temp Epoxy Tooling Board T=100mm, 500 x 1500mm£545.40 /block

Total £0.00
MOULD MAKING MATERIALS
XT135/B 415g 12k Tooling Prepreg Carbon (1250mm) 10m Roll Thumbnail
XT135B-C1212T2-415(1250)-10XT135/B 415g 12k Tooling Prepreg Carbon (1250mm) 10m Roll£745.20 /roll

XT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 2m Roll Thumbnail
XT135S-C311T2-250(1250)-2mXT135/S 250g 3k Tooling Prepreg Carbon (1250mm) 2m Roll£153.34 /roll

Total £0.00
MATERIALS & CONSUMABLES
Easy-Lease Chemical Release Agent 1L Thumbnail
ELRA-1Easy-Lease Chemical Release Agent 1L£28.50 /pack

VBT155 Self-releasing Tubular Bagging Film - 150mm - Linear Metres Thumbnail
AFVB155-015LFTVBT155 Self-releasing Tubular Bagging Film - 150mm - Linear Metres£1.36 /linear metre

BR180 Breather Cloth (1520mm) Linear Metres Thumbnail
AFBR180-152BR180 Breather Cloth (1520mm) Linear Metres£1.98 /linear metre

R120 P3 Perforated Release Film (1500mm) Linear Metres Thumbnail
AFR120-P3-150R120 P3 Perforated Release Film (1500mm) Linear Metres£0.90 /linear metre

ST150 Vacuum Bagging Sealant Tape 15m Each Thumbnail
VBST150ST150 Vacuum Bagging Sealant Tape 15m Each£5.99 /roll

VB160 Vacuum Bagging Film LFT (1520mm) Linear Metres Thumbnail
AFVB160-152LFTVB160 Vacuum Bagging Film LFT (1520mm) Linear Metres£2.40 /linear metre

Total £0.00

ABOUT VLAD YORDINOV


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