We aren't going to give away the complete formula, but here are some of the important steps in the design, manufacture and testing process behind the creation of an IPC Carbon Fiber Wing.
- The process of building a wing begins with a model or a CAD drawing.
- From the drawing or the model, we capture the specific details, specifications and dimensions. Our engineers then review and analyze the data for areas of improvement or needed design changes. From there a mold is created off a five axis router so the shape can be controlled to the design.
- We look at a wing and view it as one-piece. However, it generally requires multiple parts to complete one wing. So the engineering of the individual pieces and how they go together is critical to having a good outcome. Technology allows us to integrate complex shapes into our designs, like a wicker (gurney), on some models. It also allows us to hide seams to increase aesthetic value.
- Once the molds are made to our tolerances, we begin to test that mold with materials that simulate the use of carbon fiber. This provides us with a good prototype to test for fitment and design testing. These pre-production prototypes are then evaluated by our engineers for strength, durability and performance.
- Once engineering and manufacturing are satisfied with the quality of the pre-production sample, the IMGT3 team reviews the sample for performance once again. If it meets the original performance objectives, we move ahead with prototype building and further testing in materials such as FRP (fiberglass reinforced plastic). When the desired results are confirmed mathematically, we begin the process of building a prototype of carbon fiber for track testing.
- The IMGT3 product is constructed using layer upon layer of dry carbon fiber and infusing epoxy resins into the part. Special core materials are used in various ways to create surfaces that will not resonate under the stress of down forces created by high speeds. Some people call this “stiffness”. Stiffness is what gives consistent performance on the track and reduced deflection of the wings. All of our wings are mathematically tested to exceed the top-end performance of their matching car comparable products.
- All attachment hardware is designed to fit like original hardware. These attachment points are all reinforced with a fiber reinforced backer material that increases the holding power of the fasteners. Whether we use rivets or screws, a fiber reinforced backer is bonded with high-performance epoxy adhesive to assure the structural integrity of the fasteners. These joints have been mathematically and physically tested to ensure that we have a strong and stable attachment to the vehicle.
- When cutting the parts after molding, a five axis CNC is used to guarantee precision and accuracy in preparation for the next step.
- After passing inspection, the approved parts move to the bonding stage of production. The various components are then assembled and bonded together for an air tight fit.
- We are now ready for finishing the product and the application of the UV topcoat that gives the wing it’s high UV stable finish. This is what keeps your carbon fiber from turning yellow in tint when exposed to high UV conditions and also gives it its durable surface.
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