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challenges

CHALLENGE #001

Construction Method

The specification of these foils was high. Epoxy resin system, gel coat surface, carbon twill aesthetic on top sides and white finish on bottom side and a foam core to keep weight down. All done within cost limitations. The massive challenge here was getting the A+ carbon twill finish under a layer of clear gelcoat with an epoxy resin system.

S O L U T I O N

C-Tech decided to run with a closed-mould one-hit infusion process. This required significant R&D to ensure compatibility of resin systems between the gelcoat. C-Tech custom-built carbon mould sets were built completely in-house using the 5-axis CNC machine. The manufacturing process was refined to minimise variables and ensure product quality.

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CHALLENGE #002

Production Deadlines

A production rate of two foil sets per day was required at times to meet the production deadlines. This meant turning around both sets of moulds in a single day.

S O L U T I O N

The one-hit production process was selected for this reason. It also reduced any secondary bonding. C-Tech made use of the 5-axis CNC router and custom built jigs to trim the wing perimiter and precision drill the fastening holes. This reduced manual finishing time and ensured consistent quality and guaranteed fit to the metal mounting foot of the bike. The PVC foam core was also machined on the C-Tech CNC router so the whole process was in-house and not reliant on outside contracters.

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