FoamCore Idea.

[SteveC]

I wonder how a foamcore would behave if you used standard press techniques to laminate several thin sheets of foam together. (albeit with less pressure)
That way you could put the concave and other features into the foam itself, then fiber it up.
Thoughts, Vile objections?.

[Brady]

What about sandwiching fiber into the foam during the process too? That way you could add more strength to the concave.

[SteveC]

Yeah that could work, good idea.
Having it so it wouldn't just float in the middle would be the trick.
You'd need something to transfer the flex to and from it or it wouldn't give you it's full potential.

Doing it vertically with sine waves would pwn everything.
But Boeing/Dow-United Technologies would probably sue you...

[skatardude10]

I like the foam lamination idea! Imagine a layup like > Glass - CF - Maple - thin
foam - CF - thin foam - cf - thin foam - CF - Carbon stringer - glass

Awesome idea! I wonder how something like that would ride! Julian? Wefunk?

[lettucefresh]

it wouldn't do much. there's no advantage there, foam is so easy to bend anyways, why not just do it in one piece as the core? also, any foam core will require that it's fully wrapped either like the CF evo, or a WeFunk/ Chicago/ LF where it uses an inverted cap-sandwich.
Most of the strength from composites comes from the "shell" on the outside.
so you can make a deck like this.

Glass - CF - Maple - thin
foam - CF - thin foam - cf - thin foam - CF - Carbon stringer - glass

but i'll use this layup and mine will be stronger, lighter, and less expensive.
glass
maple
glass
maple
glass
foam
cf
glass

[skatardude10]

it wouldn't do much. there's no advantage there, foam is so easy to bend anyways, why not just do it in one piece as the core? also, any foam core will require that it's fully wrapped either like the CF evo, or a WeFunk/ Chicago/ LF where it uses an inverted cap-sandwich.
Most of the strength from composites comes from the "shell" on the outside.
so you can make a deck like this.

but i'll use this layup and mine will be stronger, lighter, and less expensive.
glass
maple
glass
maple
glass
foam
cf
glass

Oh, I see... it would still be an interesting project none the less... even if it is pointless.

[lettucefresh]

i guess you could do a stepped cap construction where each layer of foam was stepped in from last like 1/4" and beveled, that might be cool.

[wefunk]

Yeah that could work, good idea.
Having it so it wouldn't just float in the middle would be the trick.
You'd need something to transfer the flex to and from it or it wouldn't give you it's full potential.

Doing it vertically with sine waves would pwn everything.
But Boeing/Dow-United Technologies would probably sue you...

check out: http://www.elanskis.com
and then go to: Technology > Torsion > Waveflex (soft flex and torsional stiffness, very clever concept)