Reducing Defects in Composite Monocoque Frames

Along with the development of new structural materials, the study of novel manufacturing techniques becomes necessary to improve their performance and achieve optimal mechanical resistance thresholds. The present paper deals with the expedients and precautions necessary to avoid the formation of defects on carbon fiber reinforced polymers manufactured over a high-density polyurethane (PU) foam pattern. Particularly, for the attainment of a deffect-free monocoque structure for an innovative solar vehicle. The experimental campaign carried is hereby described where foam pre-treatment steps were thoroughly explored in terms of sanding and application of chemicals such as release agents and sealer. Overcoming the inherent challenge of using a yet undiffused and little known pattern material, successful results have been attained.