From aluminum plate to composite panel
A part drawn for aluminum or plywood doesn't become a composite panel by changing the material. A few details change. This is the list.
What changes
| In your metal or plywood drawing | In a composite panel | What the designer does |
|---|---|---|
| Screws or bolts straight through the panel | Foam core crushes under a clamped bolt | Adds a carbon hardpoint behind each hole. The hole stays where it is. |
| Holes under 7.5 mm | 7.5 mm is the smallest hole we cut | Enlarges them on the same centres. Use a washer under smaller fasteners. |
| Tapped holes | We don't tap threads | Through-bolt with a nut. |
| Holes close to the edge | Wants about 3 hole diameters from centre to edge | Flags the hole. Keep it and we quote it by hand, or move it the distance shown. |
| Square-cut edges | Foam between the skins at the edge | Offers a 30° core ramp to a solid border. Holes in the border need no hardpoint. |
| A 3 mm plate | A cored panel is thicker | Shows the new thickness and how much longer the bolts need to be. |
| Weight and stiffness you know | Depends on the skins and core | Calculates both against your original part, same outline and holes. |
How it works
- 1Upload the DXF you already cut.
- 2Say what it was: material and thickness.
- 3Fix what needs fixing, mostly in one click.
- 4The drawing lists every change from your file.
What stays the same
Your outline and your hole positions, unless you move one. The mating part doesn't change.
Weight and stiffness are calculated with simple beam theory, not tested. Design, loads and fit stay with you. Panel design guidelines has the full rules.