Discussions

Carbon Skin/Nomex Core sandwich panels are one of the world’s best strength to weigh materials. And it’s affordable. However,

- the edges of sandwich panels can be easily damaged.

- the panel itself is not good at handling point loads.

- the skin can peal from the Nomex with enough force.

- the edges are also not aesthetic,

But all of these issues can be fixed (see below photo).

There are several approaches to edging Nomex Sandwich panels:

o Edge, by bonding on a flat extruded carbon or plastic bar or C-channel

o Edge with caulking for lightest weight or epoxy adhesive for highest strength

o Use solid balsa core that doesn’t need edging

o Get over the sex appeal. go functional, don’t edge

But sometimes you have to edge for functional reasons:

o Drill a hole that must supports a load, like a bar going through it, so the hole has to be solid

o The area around a hole or edge has to support a side load

    … can use a washer if the load is light enough to be spread over the washer

   … if the load is high, then edging is required

o The edge is facing an impact zone or wear zone

o The edge needs to be softened (carbon on edge can be sharp)

o The skin is subject to peal forces.

In this example, a Vibration Dampened Electronics Platform (VDEP) is being built to sit within the frame of the ship (motor masts, spars, rotors, and prop cooled ESCs). The VDEP needs to hold the electronics, battery, and camera; approximately ½ a kilogram. That load goes through four holes in the Carbon/Nomex panel.

Two carbon extruded rods (axles) connect the VDEP (think car body) to the frame (think car frame and motor)  by going through via four Lantern Style dampers laid sideways (think shocks or struts)  that are part of the frame and through four holes in the VDEP. Thus the holes need reinforcement because they carry a load that is too high for Carbon/Nomex material. See photo below.  

To reinforce the holes and make the edge aesthetic and bomb proof in crashes, the edges of the VDEP were filled with epoxy adhesive (Scotch-Weld EC 2216). Note that there are many different types of fillers. And many different types of processes. This is the Ditch Route process.

Step 1: Ditch Route the shapes into the Carbon/Nomex Sandwich Panel. But first drill locating holes so the piece can be put back under the 3-axis router again for a final route and be sure to not turn the router off or save the zero point. Route through the top skin and the Nomex, but not the bottom skin. Leave the bottom skin to make it easier to fill the “ditch” with the filler of choice.

This photo shows the ditch for an inner cut-out, and outside profile, and a hole.

This photo shows light shining where the ditch is coming through the skin on the far side, which in this case is only a single ply of carbon.

Step 2: Cut the Nomex flags. The flags will interfere with the filler penetrating the cells along the edge of the cut. This goes a lot faster than it looks when using the right tool.

Step 3:  Fill the ditch with the filler of choice. Focus on the side of the ditch that matters. Cure the filler (I used an oven at 200F so the 2216 would cure in 30 minutes).

Step 4: Route the filler and panel all the way through. Use the locating holes in the panel to set the workpiece back under the router. Set z to go all the way through the panel.

And that’s one way to build a light weight and extremely durable 250 FPV flyer.