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Make Ultra Lightweight Carbon-Fiber Tubes for Model Rockets

Tim Van Milligan

This course will give you the information and confidence you need to make high-quality, customized carbon-fiber/epoxy tubes that are used in international competition rocketry. This was used by the USA team to win the silver medal in the 2021 World Space Modeling Championships held in Romania. The key to winning was having ultra-lightweight rockets made from carbon-fiber that had a low-drag surface which was a result of being a customized shape and being glass-smooth. This is the latest cutting edge in technology.

These are primary objectives of the carbon-fiber tubes made in this course:

Read more

This course will give you the information and confidence you need to make high-quality, customized carbon-fiber/epoxy tubes that are used in international competition rocketry. This was used by the USA team to win the silver medal in the 2021 World Space Modeling Championships held in Romania. The key to winning was having ultra-lightweight rockets made from carbon-fiber that had a low-drag surface which was a result of being a customized shape and being glass-smooth. This is the latest cutting edge in technology.

These are primary objectives of the carbon-fiber tubes made in this course:

  1. Light weight tubes - lighter than anything made from fiberglass cloth/epoxy

  2. Durable - strong enough to handle rough handling, and the forces of a high velocity rocket launch

  3. Super smooth surface finish - so that the tubes look good and have a low skin friction drag coefficient

  4. Air Tight - The outer shell holds air pressure, which is needed in order for the ejection charge to push out the recovery device

  5. Consistency - We want each tube we make to have the same properties

  6. Ease of manufacture - We don't want to have to be a skilled artist to make these tubes. Everyone should have success.

The keys to achieving these objectives comes down to these items:

  • Knowledge - You have to know what is important during the process, and what isn't. That is why you will find this course invaluable, because it offers you the information that isn't available anywhere else. Having this wisdom will save you an enormous amount of time and frustration.

  • Tools - Unfortunately, there is one tool — the "mold" — that is absolutely critical to making the carbon-fiber tubes. We'll describe this in detail so you can have it made to the correct specifications needed for success. Additionally, there are a number of assembly tools that will be needed in order to complete the construction of these tubes. You'll learn what they are, and how they are created.

  • Materials - The basic materials required for making these tubes are two types of carbon-fiber and epoxy. But that by itself doesn't give you a high-quality tube that meets the primary objectives. There are other "secret ingredients" which are also necessary for success. In this course, you'll be shown what they are and why they are absolutely critical to making tubes successfully.

  • Process - An example of a "process" is baking a cake from the individual ingredients. Even if you have all the correct ingredients, you have to follow a specific sequence of events and specific techniques of putting things together. What you'll see in this course are the unique techniques that aren't available anywhere else.

The result from this course is you'll be able to make tubes that are as lightweight and smooth as anyone in the world. You'll also come away with skills that you can use in other hobbies as well, like building lightweight carbon-fiber model airplanes. They can also be scaled up to make larger hobby rockets as well.

Enroll now

What's inside

Learning objectives

  • Discovery why would you want to make a carbon fiber tube for a model rocket
  • Anticipate the challenges you'll need to overcome when creating an air-tight tube
  • Identify the problems that will cause a tube to fail during construction
  • How do pressurize the mold so the carbon fiber bonds with the skin

Syllabus

You will get a broad overview of the process of making a Carbon-Fiber/Epoxy tube for a model rocket. We'll quickly go through the general steps that are involved in the process from beginning to end.
Read more

This is a quick video that gives a very general overview of the entire process, so you can see what you'll be doing when you make your own carbon fiber tubes.

In order to show the quick overview, I've left out a lot of information that will be crucial to your success. But fear not. That information will be covered in the remainder of the course.

You'll learn how to design your mold, and what parts are critical to it. The two-part mold can be make from aluminum, or plastic. You can even 3D print it if you have that capability.
What is important when designing your two-part mold to make carbon-fiber tubes?
Designing a Versatile Mold for Multi-parts - and How To Polish the Mold
In this video we'll talk about the key concept that you'll need to know in order to make the tube air-tight. Then we'll talk about the basic materials that be used and how to lay them into the mold.
Overview of the process to make an air-tight tube
The plastic liner in the tube is to prevent the rubber balloon from sticking to the epoxy. If you don't have it in the tube, you'll never be able to remove the balloon. See how to make this component.
Make the Plastic Liner Tube
The wand is what is used to inflate the balloon. It is a critical item and will have to be produced before you make your first tube. Fortunately, it is easy to make. See how to do it in this video.
Make the inflation wand that will pressurize the mold
Getting the mold to a mirror smooth surface by polishing it, and then cleaning it throughly is required before you put in the mold release. Adding release is next, before spraying the skin in.
Preparing the mold - Cleaning and Applying Mold Release
At the end of this section, you'll know the main reason why we use polyurethane paint for the outer skin coat.
Why we use this magic material for the outer skin on the mold
The specific epoxy is not critical, as long as it is thin. We'll thin it out even more, so that it can be sprayed out of an air-gun.
What type of Epoxy should you use?
The special paint is added very slowly at first - almost too whisky to see it go in. This is so that it dries quickly and doesn't run. Then it will be thickened up before adding epoxy.
How to Add the Polyurethane Paint to Create the Skin
You'll be able to adjust the rate that the epoxy is sprayed out of the gun and into the mold.
How to Adjust the Spray Gun for applying the thin film of epoxy
You'll learn the techniques of applying the thin film of epoxy into the mold using the spray gun.
How to spray in the epoxy skin-coat into the mold over the urethane paint
Here you'll learn how to cut the carbon-fiber veil, and the tow. Separating the tow is harder to do because it is so thin. We'll use alcohol to help the process of separating it.
How to separate the Carbon Tow into a wide strip
The process of putting in the carbon-fiber is shown. The secret ingredient in the process is low-tack spray adhesive.
The process of laying in the Carbon Fiber tow and veil into the mold
This step adds that nice look of precision to the final part. Not only does the tube look more professional, you'll be reducing the weight as well.
How to trim the carbon fiber to make the tube lighter
Get all the tools ready, because things go fast once you start spraying in the epoxy that bonds the carbon fiber to the skin. Here is the special tool, and what you need to perform this step.
Are you ready to button up the mold?
You'll learn how to add the final drizzle of epoxy along the seam in order to make an air-tight tube. Then you'll see how to lace up the mold so the lid can be put on.
Closing up the mold and making it air-tight
You'll see how to put the lid on and clamp it tight, and then you'll slowly pressurize the bladder in the mold. We'll also talk about what you'll have to do if the bladder breaks (unlikely).
Put the lid on the mold, clamp it tight, and then pressurize it.
Taking the tube out should be done carefully. It is still possible to ruin the tube if you are in a hurry. We'll also inspect the tube to see if it is OK and air tight. Spoiler alert: this one's a dud
Taking the tube out of the mold
This is a second demold of a tube. The process is the same, but will see that this one pops out easier than the first one.
Removing the tube from the mold
The seam is the one area on the tube that needs a little post-processing. You'll see how to sand it down, as well as trimming the ends of the tube to the proper length.
Sanding the seam to improve the looks and the aerodynamics of the rocket.
The tube is so thin, that it doesn't take heat well. So we have to prepare it for flight in a specific way.
Preventing heat damage during flight

Good to know

Know what's good
, what to watch for
, and possible dealbreakers
Provides specialized knowledge of carbon-fiber/epoxy tube construction, which can be applied to model rocketry and other hobbies like model airplanes
Details the use of specific tools like a two-part mold, which may require additional fabrication or 3D printing capabilities for successful tube creation
Emphasizes the importance of 'secret ingredients' and unique techniques, suggesting that readily available materials and common knowledge may not be sufficient
Focuses on achieving an airtight seal, a critical feature for model rockets that use ejection charges for recovery systems, enhancing rocket performance
Details the process of polishing the mold to a mirror smooth surface, which is essential for achieving a low-drag surface finish on the carbon fiber tubes
Requires access to specialized equipment like a spray gun for applying epoxy, which may not be readily available to all hobbyists

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Save Make Ultra Lightweight Carbon-Fiber Tubes for Model Rockets to your list so you can find it easily later:
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Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Make Ultra Lightweight Carbon-Fiber Tubes for Model Rockets with these activities:
Review Composites Manufacturing Basics
Reviewing composites manufacturing basics will provide a solid foundation for understanding the specific techniques used in carbon fiber tube creation.
Browse courses on Composites
Show steps
  • Research the different types of composite materials and their properties.
  • Study the basic manufacturing processes like lay-up, resin infusion, and curing.
  • Familiarize yourself with common defects and quality control measures.
Review 'Carbon Fiber Composites' by Deborah Chung
Reading this book will provide a deeper understanding of the materials science behind carbon fiber and epoxy, enhancing your ability to troubleshoot and optimize the tube-making process.
View Composite Materials: Functional Materials for... on Amazon
Show steps
  • Read the chapters related to materials properties and manufacturing techniques.
  • Take notes on key concepts and definitions.
  • Relate the information to the specific steps in the course.
Design a Simple Mold
Designing a simple mold will help you understand the critical design considerations discussed in the course and prepare you for creating your own custom molds.
Show steps
  • Sketch out a design for a simple two-part mold.
  • Consider the materials you will use to create the mold.
  • Plan how you will polish the mold for a smooth surface finish.
Four other activities
Expand to see all activities and additional details
Show all seven activities
Epoxy Mixing and Application Practice
Practicing epoxy mixing and application will improve your technique and reduce the risk of errors during the actual tube-making process.
Show steps
  • Measure and mix small batches of epoxy according to the manufacturer's instructions.
  • Practice applying the epoxy to a test surface using a brush or spray gun.
  • Observe the curing process and note any issues.
Document Your Tube-Making Process
Creating a detailed record of your tube-making process will help you identify areas for improvement and share your knowledge with others.
Show steps
  • Take photos or videos of each step in the tube-making process.
  • Write detailed descriptions of each step, including materials used and techniques employed.
  • Organize your documentation into a report or presentation.
Contribute to Online Rocketry Forums
Sharing your experiences and knowledge on rocketry forums will reinforce your learning and help others in the community.
Show steps
  • Find online forums dedicated to model rocketry and carbon fiber construction.
  • Answer questions from other members and share your own tips and tricks.
  • Document your own projects and share your results.
Review 'Model Rocket Design and Construction' by Timothy S. Van Milligan
Understanding the principles of model rocket design will help you appreciate the importance of lightweight, smooth tubes and their impact on rocket performance.
View Model Rocket Design and Construction [2008] on Amazon
Show steps
  • Read the chapters related to aerodynamics and rocket stability.
  • Learn about different rocket components and their functions.
  • Consider how carbon fiber tubes can improve rocket performance.

Career center

Learners who complete Make Ultra Lightweight Carbon-Fiber Tubes for Model Rockets will develop knowledge and skills that may be useful to these careers:
Model Maker
A model maker builds prototypes and models for various applications, and this course on carbon fiber tube creation directly enhances skills in constructing lightweight, custom components. It provides practical techniques for developing specialized parts using carbon fiber and epoxy. The course’s emphasis on mold design, material selection, and unique fabrication processes allows model makers to achieve precise, smooth finishes on custom products. The course's focus on producing lightweight and durable components is directly transferrable for use in a range of modeling applications. The course's detailed instructions and focus on manufacturability makes this course very useful for model makers.
See salaries and explore the career path for Model Maker
Composite Materials Technician
A composite materials technician specializes in the fabrication and repair of composite parts, often using materials like carbon fiber. This course on creating carbon fiber tubes provides a strong practical foundation in composite manufacturing. The course's focus on lightweight, durable, and smooth finishes is directly relevant to this career. It offers detailed instruction on creating molds, choosing materials, and employing specialized techniques for a high-quality result. The course's methods for achieving airtight seals are essential for certain applications of composite materials, making this course highly relevant for a composite materials technician.
See salaries and explore the career path for Composite Materials Technician
Aerospace Technician
An aerospace technician is a skilled professional who builds, tests, and maintains aerospace vehicles, including rockets. This course will be particularly beneficial for creating advanced, lightweight composite structures such as rocket tubes. The course's emphasis on creating smooth, airtight, and durable carbon fiber tubes directly translates to the skills necessary for aerospace technicians to fabricate high-performance components. The detailed process of mold design, material selection, and application techniques provided in this course is valuable in this field. A focus on consistency and process ensures high-quality and reliable results, aligning with the high standards of aerospace manufacturing.
See salaries and explore the career path for Aerospace Technician
Mechanical Engineering Technician
A mechanical engineering technician supports mechanical engineers in designing, developing, and testing mechanical devices, and this course can be useful for technicians working with composites. The hands-on approach of the course, which includes mold design, material selection, and fabrication techniques, provides skills directly applicable to the mechanical engineering field. Building lightweight and durable components like the tubes made in this class is valuable in prototyping and design development. A mechanical engineering technician who has completed this course will be better equipped to work with advanced composite materials.
See salaries and explore the career path for Mechanical Engineering Technician
Manufacturing Engineer
A manufacturing engineer develops processes for efficiently making products, and this course helps build a foundation in the practical aspects of composite manufacturing. The course covers various aspects of manufacturing, including mold design, material selection, and process optimization that are applicable to manufacturing. The focus on consistent, high-quality output in the course aligns with what manufacturing engineers seek in product development. The 'secret ingredients' and unique techniques taught in the course provide valuable insight into the precision manufacturing required in this field. A manufacturing engineer with experience in fabrication of composite tubes can significantly improve the efficiency of production processes.
See salaries and explore the career path for Manufacturing Engineer
Hobby Product Designer
A hobby product designer creates new and innovative products for recreational use, and this course may be useful for those specializing in model rockets or other lightweight composite products. The course provides a practical approach for creating carbon fiber tubes, a material known for its high strength and light weight. The skills learned, such as mold design, material application, and making airtight structures, are directly relevant to product development. This course helps in developing products that are lightweight and smooth. A hobby product designer who completes this course will be able to innovate with composite materials within the hobby market.
See salaries and explore the career path for Hobby Product Designer
Materials Scientist
A materials scientist studies the properties of materials and develops new materials for various applications, and this course can help those interested in composite materials. The course offers insight into the practical aspects of carbon fiber composite fabrication. The emphasis on material properties, such as weight, durability, and surface finish will be beneficial. The course's focus on 'secret ingredients' and techniques may be useful for experimentation and further materials research. The focus on consistency is useful for material scientists in evaluating results and standardizing fabrication processes, making this course useful for materials scientists wishing to better understand the practical challenges of composite fabrication.
See salaries and explore the career path for Materials Scientist
Research and Development Technician
A research and development technician assists scientists and engineers in the development of new products and technologies. This course may be useful for an R&D technician focusing on advanced materials and manufacturing techniques. The specific methods of carbon fiber tube fabrication, including the knowledge of important materials and processes, will help to understand the intricacies of composite material development. The course’s focus on the precise steps of manufacturing allows a technician to experiment with different approaches to material composition. This course's emphasis on consistent results is beneficial for any research and development work in material sciences.
See salaries and explore the career path for Research and Development Technician
Quality Control Inspector
A quality control inspector ensures that products meet established standards, and this course may be useful for those inspecting composite products. The course's focus on achieving consistent results in carbon fiber tube fabrication provides insight into the critical points of inspection. The course emphasizes the importance of surface finish, airtight seals, and structural integrity, all relevant to quality inspections. The detailed process of creating the tube, from preparing the mold to the final surface treatment, enables a Quality Control Inspector to understand where defects can arise. This ensures a high level of quality and adherence to standards.
See salaries and explore the career path for Quality Control Inspector
Science Educator
A science educator teaches scientific concepts, and this course can be useful for those teaching topics related to materials science, engineering, and rocketry. The course provides a practical, hands-on approach to teaching complex scientific concepts. The process of making carbon fiber tubes demonstrates material properties, precision manufacturing, and aerodynamic principles. The course emphasizes the importance of process, tools, and materials, making it a valuable resource for educators looking to bring real-world examples into the classroom. The educators who have taken this course can effectively convey the principles of applied science by demonstrating this process.
See salaries and explore the career path for Science Educator
Industrial Designer
An industrial designer creates the form and function of manufactured products, and this course can help those working with composite materials. The course's focus on creating lightweight, smooth, and durable carbon fiber tubes introduces designers to the properties and fabrication of advanced composite materials. The course covers mold design, material selection, and fabrication, which are important for creating prototypes. The emphasis on the manufacturing process is important for designers to understand the constraints of material fabrication. Industrial designers who understand the intricacies of composite fabrication can create products that are both aesthetically pleasing and structurally sound.
See salaries and explore the career path for Industrial Designer
Product Development Engineer
A product development engineer is involved in all stages of a product's life cycle, and this course may be useful for engineers specializing in products using advanced materials. This course will introduce product development engineers to the techniques of working with carbon fiber and epoxy. The course's focus on mold design, material selection, and the manufacturing process will help them understand the design and process for new products. The course's emphasis on achieving a high level of durability and smooth finish is important for product development engineers. This course may be useful for a product development engineer who aims to integrate advanced composites into product designs.
See salaries and explore the career path for Product Development Engineer
Aerospace Engineer
An aerospace engineer designs, develops, and tests aircraft and spacecraft, and this course may be useful for those working on lightweight structures. The course gives a deep dive into the techniques for making lightweight, aerodynamic, and durable carbon fiber tubes, which is directly relevant to the field of aerospace engineering. The course covers mold design, material selection, and fabrication processes. This knowledge enables an aerospace engineer to better understand how composite materials are used in their field. This course may be useful for an aerospace engineer who wants a better understanding of composite manufacturing, even though a typical aerospace engineer typically earns an advanced degree such as a master's.
See salaries and explore the career path for Aerospace Engineer
Automotive Technician
An automotive technician diagnoses, repairs, and maintains vehicles, and this course may be useful for technicians specializing in high-performance or custom vehicles. The skills developed in this course, such as the handling of carbon fiber and epoxy, can be applied to making custom parts. While not the typical material for auto body work, it can be useful in custom applications for performance purposes. The course’s attention to detail and consistency will help a technician create reliable and high-quality components. This course's focus on creating lightweight and durable components may be useful for those in automotive performance enhancement.
See salaries and explore the career path for Automotive Technician
Sculptor
A sculptor creates three-dimensional art using a variety of materials, and this course can be useful for those using composite materials in their work. The course introduces techniques for working with carbon fiber and epoxy to produce detailed, lightweight structures. The emphasis on mold making, material application, and achieving smooth finishes is valuable in creating composite artworks. The techniques for creating airtight forms may also be helpful for artistic and creative applications. This course's focus on achieving specific material properties may be useful to sculptors interested in exploring new materials.
See salaries and explore the career path for Sculptor

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Make Ultra Lightweight Carbon-Fiber Tubes for Model Rockets.
Cover image
Composite Materials
Save
Provides a comprehensive overview of carbon fiber composites, covering materials, manufacturing processes, and applications. It valuable resource for understanding the science behind carbon fiber tube construction. The book is particularly helpful for understanding the material properties and how they relate to the final product's performance. It serves as an excellent reference for those seeking a deeper understanding of the subject matter.
Composite Materials: Functional Materials for...
Kindle Edition
$$$
Cover image
Model Rocket Design and Construction
Save
Provides a comprehensive guide to model rocket design and construction, covering topics such as aerodynamics, stability, and propulsion. While not specifically focused on carbon fiber, it provides valuable context for understanding the performance benefits of lightweight tubes. This book is useful for understanding the broader context of model rocketry. It is more valuable as additional reading than as a current reference.
Model Rocket Design and Construction [2008]
Paperback
$$$

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Effort
5.5 total hours
Via
Udemy
Instructor
Tim Van Milligan
Language
English
Good to know
Provides specialized knowledge of carbon-fiber/epoxy tube construction, which can be applied to model rocketry and other hobbies like model airplanes
Details the use of specific tools like a two-part mold, which may require additional fabrication or 3D printing capabilities for successful tube creation
Emphasizes the importance of 'secret ingredients' and unique techniques, suggesting that readily available materials and common knowledge may not be sufficient
Focuses on achieving an airtight seal, a critical feature for model rockets that use ejection charges for recovery systems, enhancing rocket performance
Details the process of polishing the mold to a mirror smooth surface, which is essential for achieving a low-drag surface finish on the carbon fiber tubes
Requires access to specialized equipment like a spray gun for applying epoxy, which may not be readily available to all hobbyists
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