The objective of this project was to create a lightweight and durable motorbike clutch using forged carbon fibre and compression moulding techniques.
I designed the clutch lever in Solidworks while always considering how to optimise designs for manufacturing techniques. FEA of the carbon fibre part subjected to varying loads were carried out to validate my design. The model of the clutch lever was then used to create a 3 part mould. Once the mould was designed, it was 3D pritned in PETG.
After 3D printing, the parts are sanded down and coated with a release agent. A mixture of chopped carbon fibre and resin is measured out and added to the mould. Finally, it is clamped in a vice to form the final part.