Carbon Fiber Instrument Crafting
Session Number
ENGN 02
Advisor(s)
David Hernandez, Illinois Mathematics and Science Academy
Discipline
Engineering
Start Date
17-4-2025 11:10 AM
End Date
17-4-2025 11:25 AM
Abstract
This experiment seeks to determine whether carbon fiber is a viable alternative to brass or wood in woodwind construction. The benefits of using carbon fiber include weight reduction, rigidity, and price reduction when mass-produced, resulting in affordable instruments for the underprivileged. Furthermore, the material's resilience means it will not corrode like metal, making it more resistant to dents, and less likely to need costly repairs. The primary downside and reason that this is the first saxophone of its kind is that carbon fiber does not shape or tune like its brass or wood counterparts. However, we successfully constructed a carbon-fiber saxophone bell. And, while that may not look impressive, it indicates the endless possibility for carbon-fiber work on the rest of the instrument. Following the lead of the University of Illinois’ FSAE team, we prepped a mold for the carbon fiber using insulation foam. Then, carbon fiber gets applied to the mold and autoclaved to harden. Post autoclave, excess resin and fiber are filed off of the horn, also forming the tone hole that is strategically placed during the molding process. The result is a full-sized tenor saxophone bell.
Carbon Fiber Instrument Crafting
This experiment seeks to determine whether carbon fiber is a viable alternative to brass or wood in woodwind construction. The benefits of using carbon fiber include weight reduction, rigidity, and price reduction when mass-produced, resulting in affordable instruments for the underprivileged. Furthermore, the material's resilience means it will not corrode like metal, making it more resistant to dents, and less likely to need costly repairs. The primary downside and reason that this is the first saxophone of its kind is that carbon fiber does not shape or tune like its brass or wood counterparts. However, we successfully constructed a carbon-fiber saxophone bell. And, while that may not look impressive, it indicates the endless possibility for carbon-fiber work on the rest of the instrument. Following the lead of the University of Illinois’ FSAE team, we prepped a mold for the carbon fiber using insulation foam. Then, carbon fiber gets applied to the mold and autoclaved to harden. Post autoclave, excess resin and fiber are filed off of the horn, also forming the tone hole that is strategically placed during the molding process. The result is a full-sized tenor saxophone bell.