Carbon Fiber I-Beam Bridges

First iteration (left), Second iteration (right)

Cross Section Diagram First Bridge

Cross-Section Diagram Second Bridge

Diagram of Compression Testing

Free Body Diagram

Structural analysis of applied load.

Finite Element Analysis

The areas of least stress are at each end of the bridge

Tools For the Webbing

Tools For the Flanges

Sealant

Aid in Part Removal

Polishing the Tools

Clamping a Flange

Applying consistent, and evenly distributed pressure .

Vacuum Bagging

Vacuum Bagging

Webbing after Vacuum Bagging

This part needed some assistance with curing

Using heat gun

The added heat sped up the curing process, and allowed us to achieve the desired shape.

Flange Panels

Two of them are for the top and bottom, while the third was a core for the webbing.

Uni-directional Carbon Fiber Flange

This was used on our first iteration. A carbon fiber weave was used the flanges on our final bridge.

Autoclave Cure Cycle

Ply Orientation First Bridge

Uni-directional Carbon fiber for the flanges. 45 degree weave for the webbing.

Surface Finish of First Iteration

Flange

Surface Finish of Second Iteration

Flange

Surface Finish of Second Iteration

Webbing

Side View of First Iteration

Side View of Second Iteration

Testing Compressive Strength

First Iteration

Testing Compressive Strength

First Iteration experienced torsional force, so we were not able to determine the force at which it fractured.

Testing Compressive Strength

Second Iteration

Cross Section View Testing

Second Iteration Failure

Second Bridge fractured along the middle of flange, as expected.

Second Iteration Failure

Second Bridge fractured in the middle of the webbing as well.