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d. The solid parting film must be extend at least 3⁄4” onto the edge breather. e. Nylon peel ply (bleeder cloth) should extend to the outside edge of the edge breather. f. Non-perforated parting film should extend at least a 1⁄4” onto the edge breather. g. Probe pads (breather cloth) should be the size of a probe base, approximately 2 1⁄2” x 2 1⁄2”. h. The vacuum hose, probes, and gauge should be in arms reach. 4. The part being manufactured must include a ply table. (See Figure 2 on page 10.) 5. The plies in this kit have been pre-cut to size and labeled. 6. Put the plies in order with Ply 1 being on top and Ply 13 being on the bottom. 7. Verify that the plies and ply numbers match accordingly to the ply table. (Ply 1 will be on the tool side; the last ply will be on the bag side. 8. Verify that your vacuum source is working properly. Tips 1. Be sure to have all materials in order before you start the lay-up. 2. Have all bagging materials, vacuum hose, probes, gauge, and other supplies in arms reach. 3. Do a dry run to get a feel for how the lay-up will occur. Shaping the Core (Requires two chamfered sides) Create two chamfered sides on the honeycomb following the instructions. Rev A1 Pacific Coast Composites | sales@pccomposites.com | 1.888.535.1810 | www.pccomposites.com © 2017 1. 2. 3. 4. 5. 6. 7. Before cutting any honeycomb core, be sure to inspect it for any core crush, depression, or separation. When cutting core, use a sharp utility knife. Be sure to keep the utility knife straight. Cutting a full edge with one pass makes for a better final cut than making short cuts along the edge. Honeycomb core is commonly chamfered to remove any sharp edges and burrs. Chamfers also prevent crushing of parts in cure. a. A chamfer is a beveled or slanted edge of core. In order to create the chamfer you must sand away the core approximately 1” inch from the top of the chamfer to the outside edge. Sanding removes any sharp edges and creates a smooth surface for adhesive and skin plies to adhere to. Be careful not to over sand and do not sand vertically on the chamfer. You must sand horizontally with the chamfer. 3 How-to Manufacture a Composite I-BeamPDF Image | Sandwich Panel
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