I joined the WPI Formula SAE bodywork project halfway through its execution. The project involved creating carbon fiber composite parts with a carbon fiber layup. The technique that I conducted alongside the other team members was vacuum infusion.

Most of my involvement with the car was in the process of creating the plug for the car, which was done with foam. The model of the plug was sliced into 2" sections and then cut with a ShopBot. The pieces were hot glued together and multiple layers of Bondo were applied. 

The pug was sealed and sanded multiple times until a firm and smooth finish was achieved. A layer of resin was then applied to make the surface even smoother.

Once the mold was complete, sheets of carbon fiber were placed on top and then sealed with tacky tape and a vacuum bag. The vacuum infusion technique was utilized and the nose cone was successfully made. 

Although there were a few imperfections the team was satisfied with its first nosecone layup.