How To 3D Print Carbon Fiber Molds, Patterns, and Sacrificial Cores

3D Printed Carbon Fiber Molds, Patterns, and Sacrificial Cores

Learn how to 3D print carbon fiber molds, patterns, and sacrificial cores. The use of 3D printing enables fast, accurate results and complex designs without the need for handshaping or 5 axis CNC machining. This is a four part tutorial series, so be sure to subscribe for follow-up tutorials and other 3D printing news.

While 3D printing of carbon fiber composite materials provides stronger parts, the results are far from the sheer strength and strength-to-weight ratio of traditional carbon fiber parts. For this reason, carbon fiber parts are highly desirable in aerospace, automotive, sporting equipment, and applications where lightweight strength and/or elevated temperature resistance is needed.

When creating carbon fiber parts, there are two distinctive processes. In wet layups, a dry piece of carbon fiber fabric is laid in or over a mold and an epoxy resin is brushed over the fabric. A second process, called dry layups, a carbon fiber material that has been previously impregnated with epoxy resins (aka prepreg) is laid in or over your mold. The project is then vacuum bagged and, if using certain types of epoxies, may require a curing process in an oven where both heat and pressure are applied.

Why Use Additive Manufacturing

3D printing carbon fiber molds, patterns, and cores can significantly drive down costs and lead times while providing more accurate results. This process is great for prototyping, applications where customization or iterations are frequently needed, or when designs have complex geometries that are hard to machine.

3D Printing + Carbon Fiber Tutorials

The following processes are a four part series brought to thanks to a collaboration between Easy Composites and Dynamism. Find the carbon fiber process that best suits your application and hardware availability. If you have questions, feel free to reach out to Dynamism.

Carbon Fiber Molds From 3D Printed Patterns

Learn how to create production-ready carbon fiber molds for high-temp and ambient temperature epoxies.

Direct 3D Printed Carbon Fiber Molds

Learn about materials, print settings, and print preparation needed to create 3D printed molds for ambient temperature epoxies.

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