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The quality of the surface, once prepared and painted, has been evaluated for class- A and Figure 3 shows how the surface film and the CBS system as a whole compares to other technologies. Cost- effective closures The structural element of CBS was developed to give the same functionality as competing metallic technologies. The system ( including the surface film) has been designed to have equivalent stiffness to 0.7mm steel and 1mm aluminium with mass reductions of 58% and 12% respectively. To create a cost- effective structural reinforcement system, it was essential to minimise the use of expensive reinforcement fibres, adopt high drape properties and low pressure cure, and allow rapid thickness build up to full part thickness. To achieve the structural properties, while minimising the

T volunteer Experience Latin America Costa Rica . Ecuador . honduras . Peru [ be more than just a tourist ] amount of reinforcement material, a cored system would be required to separate the laminate skins and provide adequate beam stiffness. A conventional foam or core system would have incurred prohibitively lengthy and additional process cycles and added the additional complication of kitting and forming to complex geometry. Joins and core drop- outs would also read through to the A- surface and prevented a class- A surface from being achieved. The solution was to use a syntactic core - a resin film filled with microspheres. This not only gives a low- cost core system, but also maintains the drapability of the fibre reinforcement whilst greatly reducing the amount of expensive reinforcement material over a monolithic laminate. In standard form, the CBS comprises surface film, 200gsm twill weave carbon, 0.7mm syntactic core and 400gsm twill weave glass. Finite element analysis ( FEA) combined with Gurit's analytical expertise was used first to determine the CTE of each component and then later optimize each layer to give a fully balanced laminate that prevents the panel from warping with changing temperature. The glass and carbon layers each have a single resin film that is applied to the syntactic core to again create a SPRINT structure of two external fibre layers with a resin core. In practice, the assembly of this kit of materials from the individual layers allows for the joints between adjacent plies to be staggered in a scarf arrangement. This allows ply joins to be situated on class- A surfaces without the risk of read through on to the A- surface. The structural layers consist of this single pre- assembled laminate, which is kitted prior to lay up. The material system requires only two plies to be laminated to produce a part. Combined with the air evacuation properties of SPRINT, no intermediate de- bulks are required