Shop Set Up

General Composites Discussions Composites Talk
#1

A new client has a 30 x 15ft shop space we want to turn into a production composite shop. Granted it is not a big space but I think it will do.

I will be using this shop to do cf overlays, plug and mold construction. There is an additional 20ft x 15ft space that is taken up by two car lifts used for prototype and fab work.

Not sure if this sounds too crazy, but we want to overlay about 10 oem parts a day. These are small parts.

The other side of the business is plug and mold construction.

The rest of the biz is lay up work. The largest parts that will be laid up are bumpers.

Any ideas on how to arrange the lay out and work stations?
He has a few small shop vacs that can be used for dust collection in cutting/triming area. The shop is already equiped with an air compressor.

Ideally we want to lay up about 6 to 10 small parts a day AND two bumpers.

How many techs(labor) do you think it will take to: lay up these 8 small parts wet lay up-vacuum bagged no oven or autoclave; two bumpers, and complete 10 oem part overlays on small parts?

How many vacuum pumps? I’m stressed right now because i have so much work to do for this client and my own business.

Eventually I will be getting a shop space of my own that will be about 20x 20ft, and be helping this other business out a couple days a week. If things go better than i am thinking with my own business I may lease a shop that would be about 900 sq ft instead of the 20x20ft space.

#2

since you have such a limited space to work with i would suggest mounting your vac pumps and compressor up on a wall if at all possible, this will give you much needed extra work space. id also say to have one wall exclusively for storage of moulds/materials/tools etc. this way you only have one area (immediately in front of storage area) to keep clear at all times as a couple of bumper take up quite a bit of space and may prove difficult to move after laminating. other than that get going and work it out as you go, too much planning can just confuse the matter sometimes. good luck.

#3

Sounds like space is very limited! My tooling area is 2,500 sq ft and there isn’t room to spare for molds to sit very long.
I suggest working alone and see how much you can get done. Then good luck finding someone that can also do the same composite work, and most likely their productivity will be low while they learn the basics.
Doesn’t sound like there’s space for plug construction, mold making, AND production in the same area. Plan the projects carefully and use the space for different purposes each day. Figure out how materials will be stored cleanly and the resin mixing area will not contaminate other projects.
Plenty of vertical storage helps!

#4

I would not mount the compressor on the wall unless you enjoy washing the walls. I made this mistake & the vibration from the compressor caused constant dust storm.

Before anyone asks it’s not a POS compressor.

#5

That looks like a great compressor Joe. Can i borrow it? LOL.

I’ll have to buy a compressor for my own shop in a few months. I love having air to pop the parts out of the molds :slight_smile: Plus air tools for plug construction is a great thing to have.

Yeah i was thinking some areas of this guys shop space will need to be multi-purpose. For smaller molds there is plenty of vertical storage and he has a space in back of his offices where cloths can be stored on his composite roll rack. Bag film and peel ply will probably get stored in the shop and covered up to keep the dust off them.

I was thinking of setting up one of the walls with a long bench for two or three vacuum bag stations for small parts… each area about 34"x30" x 3 of those. Another wall area for overlays ( all the parts we overlay are small) so probably a 6ftx3ft bench for that. Just sand, and trim the parts outside the big roll up door, and have a shop vac with attachment for helping to suck up the dust.

Middle shop floor have two or three bumper size molds being laid up/vacuumed. I was thinking of dropping 3 vacuum lines from the ceiling. Which leads to my next question: quick disconnects. I use a regular air compressor line quick discconects on my vacuum pump to resin catch pot…it never leaks vacuum. I have heard people say those leak?? I also wrapped the connections with sticky tape, not the sleeve you pull to connect to the male fitting… I don’t wrap that. I wrap the hose clamps with sticky tape. So I’m wondering if I should take a chance and use 3 of these same set ups in his shop?

If not… here is the hose i use for vacuum: 3/8"i.d.x 1/2" o.d. polyethelene. I figure 3/8 I.D. because we want to vacuum those bumper lay-ups. Should one line be a low hg (10) for debulking running off of a seperate vacuum pump?

#6

How about putting in a mezzanine floor over part of the work space. That way you could add up to double the floor space. You could use plastic sheeting to stop dust movement. Lay up on the upper level and trimming and other dusty stuff on the ground floor or storage/ office upper level, work on the ground floor.

#7

That is a good idea. :slight_smile: mezanine.

I hope to be setting up my own shop soon. I got to make some molds and sell the parts first however.

Where did you buy that air compressor Joe?

#8

if you find that your aro couplings leak, though i doubt they will, you can put a small envelope bag around them. easier to remove than tape and you can see for sure if it leaks by the bag being vaccd.