To achieve the best strength, layer rigidity, consistency, and visual opacity, the researchers developed winding pattern consisting of three repeating steps: (1) peak winding – to generate a stable and consistent form, (2) valley winding – to connect the structure’s low points, and (3) spiral winding – adding a third layer of FRP on all the intersecting panel edges. Each step consisted of four unique layers of wound carbon FRP. After completing one full winding cycle, the winding direction was flipped 180 degrees and restarted.
After winding, the structure was baked in a large 6.5’ x 5’ x 5’ gas-fired kiln at 260 F. Unlike applied resin systems that contain an additional hardener, the researchers used a heat-activated resin preimpregnated in the carbon fiber, which required extremely precise curing times and temperatures. Upon cooling, the structure’s steel formwork was removed from the composite shell.
For more details, click here to ready the full study by authors Andrew John Wit, Simon Kim, Mariana Ibañez and Daniel Eisinger.
