Carbon Fiber Spoon

John Kestner - Techniques for Design and Fabrication, Fall 2008

For my carbon fiber assignment, I decided to make a spoon. (Click on a picture to see more detail.)

  1. I coated the spoon I was using as a mold in the waxy mold release. I probably didn't use enough because I wasn't sure whether lumps would show up in the finished product.
  2. I cut carbon fiber into the right shape. Scissors cut this stuff really easily.
  3. I spread epoxy on one side of the carbon until it looked wet all over, though not saturated. I probably didn't use enough of this either, since later I got a couple of dry spots that frayed a bit when sanded.
  4. I draped the sheet over the spoon and pressed it down and around. Then I put a bit more epoxy over it.
  5. I put some clamps to keep it in place as it cured. Around this point I thought about how much easier it would've been if I had had another of the same spoon to press on top, and clamp the carbon fiber between.
  6. After curing for a little while, I put a second carbon fiber sheet on top of the first, and again, spread some more epoxy on top of it.
  7. I hung it up to cure completely for about two hours.
  8. I trimmed away as much of the excess carbon fiber as I could with scissors. It was a lot tougher after being impregnated with epoxy.
  9. I sanded the edges and surface smooth, first with 150 grit and then with 300 grit. I wet-sanded to keep the carbon dust to a minimum.
  10. It came out semi-gloss and smooth. As said before, a little more epoxy would've been good. The back side had a glossy shell of epoxy, where the mold release was applied well. Otherwise it got stuck to the spoon in pieces.

    While I made sure to curve the sheets around the neck of the spoon to give it some strength at the narrowest point, as soon as it flattens out, it twists very easily. Maybe I'll do one more layer of carbon fiber on the back side and apply a thicker coat of epoxy. I may also cut it into a spork.