In February of 2021, I launched a composites manufacturing business, creating non-structural fiberglass and carbon fiber components for dirt Sprint Car racing. Composite materials have been a key interest of mine since 2020 due to their high-performance properties and their use in motorsports and aerospace applications.

What started as research in 2020 developed into the purchase of equipment to manufacture carbon fiber composites using the vacuum-assisted resin transfer process. This process is advanced for at-home composite manufacturing due to the complexity of vacuum pumps, extensive mold setup, and bagging consumables.

The process I use to manufacture these is called vacuum-assisted resin transfer molding (Shown in the figure on the left). In this process, I use a fiberglass mold to produce dimensionally accurate, detailed components. 

The VARTM process produces minimal air voids in the finished part and an optimal resin-to-fiber ratio, creating strong, lightweight components.

Components of the VARTM process:

• Rigid mold; typically made out of fiberglass

• Laminate stack of carbon fiber

• Vacuum pump

• Vacuum bagging consumables

• Resin

My goal for this exploration into composite structures is to provide high-quality components for myself and other race teams at a fraction of the cost major companies charge.

Racing is an expensive hobby; manufacturing our own body panels allows my team to lower operating costs while generating revenue that can be reinvested in the race team.

This also expands my knowledge and expertise as an engineer. Composite materials are widely used in aerospace for their high specific strength. Gaining hands-on experience with these advanced materials provides a broader understanding of what is possible beyond standard metallic components in industry.