Composite Lay-Up & Preparation:

• Prepared and precision-cut carbon fiber sheets to match the complex surface profiles of pre-machined foam core molds.

• Executed a detailed wet lay-up process, ensuring flat, wrinkle-free material alignment across the mold contours to prevent structural weak points.

Chemical Matrix Integration:

• Formulated a high-strength epoxy resin matrix, strictly adhering to precise stoichiometric mixing ratios to ensure optimal chemical cross-linking.

• Applied the epoxy uniformly across multiple carbon fiber plies, ensuring complete wet-out and structural saturation of the fabric matrix.

Vacuum Consolidating & Curing:

• Integrated a vacuum-bagging system to apply uniform atmospheric pressure across the laminate assembly overnight.

• Maintained consistent pressure to squeeze out excess resin, eliminate internal voids, and maximize the fiber-to-resin volume ratio for high-strength bonding.

Post-Cure Finishing & Assembly:

• Utilized rotary tools, precision abrasives, and hand-sanding techniques to post-process the cured surfaces, eliminating aerodynamic surface blemishes.

• Aligned, mated, and permanently bonded the symmetrical fuselage halves using structural adhesive to complete the aerodynamic shell assembly.