For my carbon fiber assignment, I decided to make a spoon. (Click on a picture to see more detail.)
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.
I cut carbon fiber into the right shape. Scissors cut this stuff really easily.
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.
I draped the sheet over the spoon and pressed it down and around. Then I put a bit more epoxy over it.
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.
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.
I hung it up to cure completely for about two hours.
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.
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.
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.