Next, the sheets are laid up against the foam mold (figures 4 and 5). The mold consists of two long foam pieces on either side of a metal piece (figure 6). The mold is constructed in this way so that the metal piece can easily be pulled out and the mold separated non-destructively from the carbon fiber after it has been baked. The carbon fiber strips are wrapped on the part at 30 degrees and 150 degrees so that the unidirectional fibers provide extra strength.
Last, the part is covered in plastic (figure 7 and 8). Tape is applied to seal the air in. A hole is put in the plastic so that the air can be sucked out of the plastic. When all of the air has been removed, the part is put in the oven (figures 9 and 10).
The final piece is in the picture below (figure 11).