setting up my shop

General Composites Discussions Composites Talk
#1

As I am setting out to improve my shop to provide better quality products; thought I might ask if anyone else has built a clean room and spray booth.
If so did you learn anything that you might wish to share as I move forward?

Clean room is small, 8x10 with a filter system that provides 100% fresh air.

Spray booth is 8x9 and uses the same filtration system
I can use filters that will get down into the microns, not sure how crazy to get with that issue.

I have a fabric cut room that will have cut tables with downdraft filteration.
Also building a wet sand/polish/wax room with a second filtration system.
The cut and grind shop will be sealed off from the production area.

Thanks,
Joe

#2

Perhaps it would be nice to know what you are making, form which materials, and what the demands are. If you are able to remove the cutting and grinding area from the production hall, and the same for cutting fabrics, then you already have 95% of the dust sources covered.

#3

Carbon fiber finish parts, black and other color finish fiberglass parts.

The cut and grind area will be divided by a firewall and on a separate filtration system.

#4

I think he realizes you’ll be making some composites. I assume the question was more geared toward what type of industry the products are used in. Aviation, automotive aftermarket, automotive OEM, amateur motorsports, professional motorsports. And also the type of products. Are they structurally loaded items, such as suspension links, etc.

What requirements do you have from your customer in terms of quality, defects, inspection techniques following delivery, etc. That type of thing.

#5

Automotive,
Intake ducts, air boxes, ram air ducts and some parts for UTV’S as of now.
I will post some pictures this weekend when I have some time.

#6

I think installing a cleanroom is overkill then. Just organise your shop smartly, and keep it neat and tidy.

#7

Filtration is key for good professional parts that should not have cross contamination. “Cleanroom” might be overkill, but just go along with what you have and sort it out from there.
Make sure you have your tools release coated in the spray booth, NOT layup/cutting area. Release in the air that attaches to the fabric will cause interlamination issues.
How are you having a downdraft cutting table? Are you cutting only by scissor? I think downdraft, and think of a large metal grate. Hard to cut on that!

#8

The clean room is something I have to build to address some health issues I face, I have it framed and the ceiling is in, the design of the downdraft air flow system is working well. I have the booth about completed, a door and the explosion proof light fixtures are the remaining items to complete.

The down draft cut table is my next big issue to overcome, have some ideas to try will post on the outcome once I get past what does and doesn’t work.

Thanks for the helpful post!
All the best,
Joe

#9

I don’t think a 8x9 or a 8x10. I did a 8x8 and I have a hard time with painting bumpers and long parts.

http://www.flickr.com/photos/28631797@N03/sets/72157627614674501/

greg

#10

Hi Greg,
With that set up, do you have a dust problem. I also built up my own spray booth with 8’x8’ size. with two exhaust fan on each upside corner, but still have the dust on the clear coat surface. any idea?

#11

Filter your incoming air. That is the idea of a cleanroom.

Also enter with cloths that do not generate dust. Cover your hair and your mouth. Use sticky mats to get rid of dust from your shoes.

#12

Making sure that you have balanced air in/out helps as well . Having filtered air enter into the room down low and then exiting up high will prevent dust from settling on your wet parts .

#13

I outsource my clear coating. I learned the hard way that sometimes its better to just pay someone else to do some things so you can make money doing what you do.

#14

The professional paint booths I have seen have the following in common:

[ul]

[li]Filtered air intake and exhaust.
[/li][li]Positive pressure air input (more air goes in than the exhaust fans can pull out on their own) This helps prevent dust from being pulled in through any cracks.
[/li][li]Air enters high and exits through the floor. This has 2 effects, first dust stays trapped on the floor. Second solvent vapors evaporate more quickly since air is being pulled over the painted object.
[/li][/ul]

In Germany it takes 7 years to get a master tradesman certificate. Before that, you cannot open your own business. I’m not going to be able to replace that kind of training by trial and error in a few weeks. Like 2Tall said, outsource your painting if you want professional results.

#15

Its highly worth it for me. I’ll manufacture a part for $400, make $300 of profit, and then pay $40 to have it clear coated. I charge the customer an additional $40 on top of the $400 so it costs me nothing. Same with anything else I do.