00:00Comment on va-t-on partir de ce papier-thin de carbon fibre
00:03all the way through the process
00:04to a fully foiling F50 racing machine?
00:07Il va-t-il à l'intérieur, on va-t-il à l'intérieur.
00:10Look at the speed!
00:12Carbon fibre.
00:14C'est le secret behind speed and strength
00:16in Formula One, Cycling, Aerospace and SailGP.
00:20Mais qu'est-ce que c'est carbon fibre?
00:22Et où est-ce que ça vient ?
00:26Carbon fibre est composé de carbons atomes
00:28arranged in a crystalline structure
00:30often resembling graphite
00:32with layers of repeated hexagonally arranged carbon atoms.
00:36Before you can lay carbon fibre
00:38often pre-impregnated with resin
00:40known as pre-preg,
00:42you need a mould for the shape you're making.
00:44The composite team worked to a drawing
00:46with a technical specification
00:48with information like how many layers,
00:51what type of carbon fibre to use
00:53and how to lay it at different angles
00:55for particular strength.
00:57This is crucial
00:59as not only does every part need to be the same
01:01but it needs to be built to the engineer's specification
01:04for performance and safety.
01:06This is your instruction manual.
01:08So what we go from that floppy bit of carbon,
01:10how does that actually turn into the solid piece
01:12that you're trying to make?
01:13So this is just the first skin which is done here.
01:16We laminate all of these with your orientations and material.
01:19We then bag it up for a cure,
01:21it goes taken to the oven and cured.
01:23So you're going to lay up how many layers here?
01:25So these layers here,
01:26you've got 11 layers in total.
01:28Okay, this is layer one.
01:29This is layer two, I'm on now.
01:30Okay, so that's layer one.
01:32And you cross the weights?
01:34Yes, so all the different orientations are here
01:37and then these are just reinforced,
01:38the last six plies are just reinforcements.
01:41So if you look at these measurements that I've done here,
01:43they're where the reinforcement patches sit.
01:46Right, okay.
01:47Once this skin is cured,
01:49it then comes out,
01:50we remove the peel ply and then the glue film
01:52and the 50 kilograms aluminium gets put in.
01:56Is it curing now?
01:58Because whenever I do anything with carbon,
02:00I'm panicking about,
02:01I've put my epoxy on and I'm like...
02:02This is pre-preg.
02:03So epoxy resin,
02:05obviously you've got time for it to cure off,
02:06but this is pre-preg.
02:07This won't cure until it's put in an oven or a clay.
02:10Okay, so you're going to lay it up here.
02:12Yeah.
02:13And then you're going to move it somewhere.
02:14Yes, it'll be bagged up and put into the oven to cure.
02:16Then it will come out and it'll be solid.
02:18And how long is it going to take to get,
02:20without me talking to you,
02:21completely ruining your day?
02:22I've gone until the end of today to get this in the oven.
02:24Okay, fair enough.
02:28So you lay all that down on our different angles.
02:31And how do you cut them by hand?
02:33Yes.
02:34All cut by hand.
02:35I cut most of it yesterday.
02:36I've still got a bit to cut today.
02:37Okay.
02:38Let me pull that around.
02:39Fair enough.
02:40Well, it seems fairly accurate.
02:41It's only we always hear Tom saying to me whinging
02:43that everything's not quite the same.
02:45It's not fair on it.
02:46I just wanted to check it.
02:48Tom, it is all the same, mate.
02:50The next stage is to seal a vacuum bag around the structure.
02:56This sucks the air out of the layers to consolidate the carbon fibre.
03:00Hey, Kieran.
03:01How you doing?
03:02Good to be.
03:03I just got sent over by Mickey because he said,
03:05after we've just been doing the phase of laying up parts of things,
03:08we've then come over here and this was the next section involving a bit of vacuum bagging and stuff like that.
03:13So what is it that you're up to?
03:15So right now we're laying our pre-prick right now.
03:18Just doing some pliers of pre-prick.
03:20On our 96 pliers so far.
03:23So once we do this, we debulk it to get all the air out, all the bubbles out.
03:28Get all the bubbles out.
03:29What do you mean by that?
03:30Just basically consolidate it basically.
03:32Just like get all the wrinkles out, make sure it's perfect.
03:35And then we'll be ready to put on the next layers.
03:38Okay.
03:39So more layers are going to go in here.
03:40More layers, definitely.
03:41Okay.
03:42And then we're going to what?
03:43This is coming into it, is it?
03:44Yeah.
03:45So.
03:46What's that going to do?
03:47This is a pre-prick of film so it doesn't stick.
03:51It allows the air to go through and nothing sticks through it as well.
03:53Yeah.
03:54And then this is a mesh.
03:56It allows the air to flow through it.
03:57Yeah.
03:58And this is just a bag to keep it down, backing it down basically.
04:01And then we've activated it down.
04:02Why do we need to do that?
04:04It takes to replace of like, you know, a steel roller.
04:07Okay.
04:08So it's stronger, it's more pressure.
04:09Okay.
04:10So it's just going to suck it down into the mold and make sure it's the exact shape we want.
04:13Make sure everything is flat and smooth.
04:15Okay.
04:16So there's no voids underneath it.
04:17So there's no gaps in between the layers.
04:18Probably.
04:19Yeah.
04:20Okay.
04:21So it's just pulling it all together so that we know that it's going to be exactly the same shape.
04:23Exactly the same strength.
04:24Yes, exactly.
04:25And there's no voids in it that can then break.
04:27That's the angle.
04:28Right.
04:29Then it will get NDT'd.
04:30It will come and scan it to make sure it's nothing.
04:32Okay.
04:33So NDT's a scanner?
04:34Yeah.
04:35The guy will come and make sure there's no pieces of like material underneath the carbon.
04:39Okay.
04:40They can see it all in a scan and make sure there's no voids and stuff as well.
04:43So, and then they will either say it's good or not good.
04:47Basically.
04:48So next stage is the oven?
04:49Yeah, basically.
04:50So where do I find that?
04:51That's the big building over there to the left.
04:54Okay.
04:55Yeah.
04:56That's cool.
04:57Thank you mate.
04:58Take care.
04:59Okay.
05:00Well, I've made it across the factory floor.
05:01This is where Kieran sent me.
05:02This is the oven.
05:03Absolutely huge.
05:04It is over here.
05:05We can see the parts are in there.
05:06They're going to turn on the fans, heat this thing up.
05:08Too hot for me.
05:09I'm not willing to get in there, but what we will do is go across the factory floor and
05:13find the finished product.
05:14The last step in the process is the fit out and finishing of the product.
05:19Take the hull, for example, further strengthening of certain areas that need to be reinforced
05:24to help different crew and parts of the F-50.
05:27We made it across.
05:28Come across Francis.
05:29Yeah.
05:30Nice to meet you.
05:31I've just come across from the oven.
05:32We're sort of trying to follow the journey of all the parts here.
05:34Yeah.
05:35So what's going to happen next?
05:36So at this stage, it's had all its fit out done.
05:39So the cockpit floor has been put in.
05:41All the bulkheads have been put in and the wet box has had all its work done ready for
05:45the foil case.
05:46The next step after this is for the decks to arrive and then we bond the decks on top
05:50and it becomes a whole hull.
05:52Okay.
05:53So this is the foil box.
05:54This is where the foil is going to go down.
05:55So what are you doing right down in here then?
05:57So down in here, we're just reinforcing a part.
06:00That's where the dual ball sits, which is the part that the foil case is mounted onto.
06:04Okay.
06:05So the shelf has been stuck in and then we're laminating around it.
06:08It's kind of reinforced.
06:09Okay.
06:10So do you put in any extra layers for Nikolaj Sehersted and the Danish team?
06:13Is that a thing or is it?
06:14A couple of things.
06:15Okay.
06:16Right.
06:17Fair enough.
06:18But this, so what we've got going on here, that's a vacuum bag.
06:19Yeah.
06:20So that's just sucking it on super tight.
06:21Yeah, exactly.
06:22So it's sucking on super tight and then you're kind of drawing some of the resin out as it goes.
06:25So those bits I can see there, that's new.
06:27Yeah.
06:28So that's still yet to cure, I guess.
06:29And this bit's out of the oven.
06:31Is that now finished?
06:32So it's pretty much there.
06:33All it needs now is a good sand up and then we'll concrete seal it, which is all that part in the hull.
06:39Okay.
06:40So this bit here.
06:41Yeah.
06:42So concrete seal.
06:43Yeah.
06:44That sounds heavy.
06:45No, it's like, it's just like a really weird paint basically.
06:47Okay.
06:48It's quite thin.
06:49You just rub it on and then it protects the carbon.
06:51Okay.
06:52Yeah, exactly.
06:53Okay.
06:54Kind of seals it.
06:55Right.
06:56Fair enough.
06:57And then once you've done that, then we're going to put the top on it.
06:58Yeah.
06:59And it's good to go.
07:00Pretty much.
07:01We need to do some more fit outs.
07:02All the little details in the cockpit, like the pedestal and like the steering wheel mounts,
07:06all those kind of things will go in once the deck is on and that's kind of the finishing touch.
07:11And are you going to follow that the whole way or are you specialising in just this area?
07:16I'm kind of jumping on whatever I can get my hands on to be honest and just kind of learn as much as I can.
07:21Okay, cool.
07:22Yeah.
07:23So we're going to get the box done.
07:24Has this got to go back in the oven?
07:26No.
07:27So once it's gone off, it'll all be fine.
07:29And then the next part will go in and it'll be back down.
07:32Okay.
07:33And what stage do we put the top on it?
07:34When do we put the decks on?
07:35So the decks are arriving tomorrow and in a couple of weeks time.
07:39So it'll be pretty much as soon as these are finished, which only a few more things need to be done.
07:44So maybe another day or two is work.
07:46The decks will go on and then we'll start doing that stuff.
07:50Okay, so the deck goes on and it starts to look like an F50.
07:52Yeah, exactly.
07:53Okay, perfect.
07:54Thank you very much for your time.
07:55That's alright.
07:56Thanks.
07:57Okay, well we've been through the cutting process.
07:58We've then laid it all up.
07:59We've proofed it.
08:00We've had it scanned to check there's no faults in it.
08:03It's been in the oven over there, cooked.
08:05It's nice and solid.
08:06It's had those final touches we've seen.
08:08And now from a carbon perspective, it's all finished here.
08:11We're ready to go.
08:12Doesn't look the prettiest just yet.
08:13We're going to put the electronics in, the hydraulics, get the branding on for which other lucky team will take this boat.
08:18But yeah, we've followed the carbon on its journey.
08:20From that flexy little bit of carbon, we've now got a solid F50.
08:43All right, let's bet.
08:44All right.
08:45All right.
08:46Let's see.
08:47Let's see.
08:48I'm looking.
08:49Beautiful, all right.
08:50Yes.
08:51Cor dilemma – in the within 3 hours, but Eating us with memorellum...
08:53Not necessarily the is only mammal and the Seven-ymphal Cann sharmin.
08:54However, this retails from Mojana.
08:56I'm not sitting with a dog sang acá on his family.
08:56Place ton?
08:57I'm on a date.
08:58I'll watch his walk and inspire him.
08:59I'm not at this university now.
09:00I am looking.
09:01Guys, we're taught them you to sleep.
09:02We are interested nickn 2 to 4 hours ,
09:04please.
09:05I'm ageh.
09:06If it gets sized, he's so natural and��,
09:08then it's truly pleased.
09:10Viel effort is most vulnerable.
