Project summary

Over my last semester in college (spring 2025) I was a TA for the composites class (ME 114) at Tufts. While I did a bit of grading, my primary responsibility was to guide students through the composites manufacturing process – from design, to layup, to infusion. The course consisted of two phases: the first phase was aimed at teaching students the basics of composites manufacturing while the second phase gave students free reign to make any composite product they wanted.

Phase 1 – Flat Panels & Testing

During this phase I guided students through the process of creating small flat panels out of carbon fiber, kevlar, and fiberglass, using both wet layup and resin infusion. The students then waterjet cut ASTM test bars from these panels to tensile test with an Instron and compare material properties. The photos below show some highlights of this phase.

Sanding the flat mold to make a smooth surface
Wet layup of carbon fiber and fiberglass panels
Resin infusion of carbon fiber and fiberglass panels
Result of resin infusion

Phase 2 – Group Projects

In this phase, students are allowed to make a composite product of their choice. The four groups consist of a carbon fiber steering wheel (for Tufts electric racing), carbon fiber guitar, carbon fiber car mirror cover, and fiberglass boomerang. Some photos from the process are shown below.

Wet lay of CF on mirror cover mold
Vacuum bagging of mirror cover wet lay
Carbon fiber/core infusion for steering wheel
Waterjet cut and grips installed on steering wheel