For my next project I want to attempt to make a carbon fiber helmet. My budget is fairly limited as I want to spend less than $200 and preferably closer to $100-$150. I also wanted to sculpt this helmet. Because of this and the high cost of a traditional silicone mold, I was wondering if I could apply the carbon fiber directly to oil based clay given that I use some kind of releasing agent. If this can't be done, is there a way to mold a full-sized helmet for around $50? Any advice is greatly appreciated.
Can I Put Carbon Fiber Directly onto Oil-Based Clay?
- Thread starter Fractals
- Start date
Cheapest solution to making molds that I know of is probably fiberglassing. You can get fiberglass sheets and the resin fairly inexpensively along with a proper respirator. Look up some videos for it online; there are plenty to be found on the subject.
Either that or using loads of plaster and hemp.
Either that or using loads of plaster and hemp.
If I made a fiberglass mold, wouldn't the cast polyurethane piece just stick to the mold? Also I don't think this would work for a helmet as it would require a two piece mold or a throwaway mold, and that would be hard with purely fiberglass. My other concern is capturing detail.
Also, if I stuck fiberglass onto the clay, wouldn't I might as well just put on the carbon fiber, as they are essentially the same, just a clear resin and different fiber in the cloth.
But about the plaster, could I just make a plaster mold, pull out the clay, and cast a polyurethane helmet? I could just tear the plaster off as I only need one pull.
MrSouthpaw
Sr Member
Carbon Fiber can be a hazardous material in some cases. The shards can enter you skin and stay there for life. You can breathe them in and they stay in your lungs forever. And you just happen to be making a helmet.
If you really need a carbon fiber helmet due to it's properties. I would suggest buying a factory made one.
If you just want it to look like carbon fiber. There are hundreds of products out there to simulate the look.
If you really need a carbon fiber helmet due to it's properties. I would suggest buying a factory made one.
If you just want it to look like carbon fiber. There are hundreds of products out there to simulate the look.
If you make and cure it properly shards aren't going to fly into your lungs. Also if that was true then it would be the same for fiberglass helmets, which people make all the time... So I don't know where you are coming from. I appreciate the concern, but I'm asking for help not safety warnings, I can get that off the back of the bottle
Marchogwyn
New Member
I know that you can release clay by spraying it with a shellac, and then a coat of release agent. The kind of release would depend on what kind of resin you use with the carbon fiber. If you are just using a polyurethane resin the something like Ease Release 200 should work fine. I think that stuff will work for epoxy resins as well but you might want to do some research beforehand. As for the method of putting resin impregnated carbon fiber directly on top of a sculpted clay positive; I don't think that will retain the detail without a vacuum bag. Though if you do pull a vacuum on it, it will distort the clay. Really, in order to get that sweet seamless carbon fiber look, as well as the structural properties that come with it, you would need a negative mold of the helmet, and you would need to pull a vacuum on it.
MrSouthpaw
Sr Member
Just because they both contain the word "fiber" doesn't mean they are the same, work the same, or have the same health risks....:rolleyes
Its a composite based off a flexible cloth made of woven strands and strengthened with resin, so they are pretty similar and have the same health risks.
MrSouthpaw
Sr Member
That's a gross over-simplification that ignores the vast material differences between them. You could literally apply that description to cotton cloth coated in pine sap.
But I'm not. You said shards would fly off. These "shards" would be made of hard bits of the composite material, the cloth. They are hard because of the resin. Thats how fiberglass is..
MrSouthpaw
Sr Member
Yes, shards of the raw carbon fiber. They are a health-hazard all by itself. Never said anything about it needing to be coated with resin. So when you're handling it, you are already exposing yourself. Carbon fiber can also fuzz and dust up from handling. Which are both even bigger hazards to the lungs.
I'd be wearing a respirator while working with it, and once the resin is put on and cured nothing is gonna fall off.
Rogviler
Well-Known Member
Oh my god you guys...
I think you'll be fine going on top of the clay. As has been pointed out, you'll lose detail, such as you would with vacuforming. You have a lot of cheap options for a one-time mold. Plaster is good. There's also making a fiberglass mold but using polyester fleece ($3/yard) instead of fiberglass cloth. Once the final helmet is cast, just carefully cut the mold in half and chuck it. Or do a two-piece mold and have a seam to sand.
If you just want the look of carbon fiber, my first choice would be a film transfer, where they dip the piece in a tank that has basically a sticker floating on top of water. Might be pricey if you have to send it out but it looks 100%. Second choice would be 3M 1080 vinyl. That would be a bear to do on basically a sphere if you can't hide a seam or two. Third choice would be a faux paint technique. I've seen some really good ones, but you'd have to practice a bit.
It would probably help if you posted more details. Otherwise it's a lot of shots in the dark.
-Rog
I think you'll be fine going on top of the clay. As has been pointed out, you'll lose detail, such as you would with vacuforming. You have a lot of cheap options for a one-time mold. Plaster is good. There's also making a fiberglass mold but using polyester fleece ($3/yard) instead of fiberglass cloth. Once the final helmet is cast, just carefully cut the mold in half and chuck it. Or do a two-piece mold and have a seam to sand.
If you just want the look of carbon fiber, my first choice would be a film transfer, where they dip the piece in a tank that has basically a sticker floating on top of water. Might be pricey if you have to send it out but it looks 100%. Second choice would be 3M 1080 vinyl. That would be a bear to do on basically a sphere if you can't hide a seam or two. Third choice would be a faux paint technique. I've seen some really good ones, but you'd have to practice a bit.
It would probably help if you posted more details. Otherwise it's a lot of shots in the dark.
-Rog
MrSouthpaw
Sr Member
Rogviler
Well-Known Member
Hmm, interesting. I'd be too scared, both because of how delicate the operation is and because of the "What did you do to the bathtub?!?" aspect.
-Rog
MrSouthpaw
Sr Member
It's not that delicate. Just needs steady enough hands. A tighter pattern of course would require a bit more care, but still.
https://www.youtube.com/watch?v=7YatFSGjRMo
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