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DOI: 10.21062/m .2020.038 © 2020 Manu ac u ing Technology. All igh s ese ed. h p://www.jou nalm .com
Applica ion o Composi e Ma e ials in Spo s Op ics
Radim Kupčák, Jan Zouha
Facul y o Mechanical Enginee ing, B no Uni e si y o Technology, Technická 2896/2 616 69, B no, Czech Re-
public, E-mail: 170299@ u b .cz, [email p o ec ed]
CFRP (Ca bon Fibe Rein o ced Polyme s) a e o en used when designing pa s ha need o be s i ,
ligh and he mally s able. These bene i s a e a big mo i a ion o use CFRP in many applica ions, one o
hem could be spo s op ics. Howe e , op ical de ices equi e p ecise dimensions wi h igh ole ances
o he op ical assembly o wo k co ec ly. In o de o de e mine i CFRP could be a sui able ma e ial o
choice o spo s op ics a simpli ied body o binocula s was designed. The ubula body was manu ac u-
ed by p ep eg lay-up in o a 3D p in ed mold, ollowed by cu ing in an au ocla e. A e he p o o ype was
manu ac u ed 3D measu emen s o he ube using 3D scanne GOM ATOS we e made. As expec ed,
sh inkage o he mold and he epoxy esin in he ma ix o CFRP caused mino de o ma ions. Howe e ,
i he shape o he cu ed pa emains unchanged du ing condi ions simila o he gene al use o binocu-
la s, hen he ini ial de o ma ions happening du ing manu ac u ing could be accoun ed o when desig-
ning he pa .
Keywo ds: Ca bon Fibe , Spo s Op ic, P ep eg, Composi e Ma e ials, 3D scan
In oduc ion
Composi e ma e ials, speci ically CFRP (Ca bon
Fibe Rein o ced Polyme s) ha e ecen ly become
mo e and mo e accessible as a s uc u al ma e ial.
They ha e become so wide-sp ead because o new
echnologies ha make manu ac u ing and use o
CFRP cheape and mo e con enien . These new ech-
nologies o en o e high le els o au oma ion and
sho p oduc ion imes. This allows o use o compo-
si e ma e ials in mass p oduc ion indus y segmen s
such as lowe -end ehicles p oduc ion, which has no
been he case ea lie . Tha can lead o signi ican
weigh educ ions, which could compensa e o he
ba e y weigh in elec ic ehicles, making hei o e all
weigh mo e easonable. [1]
On he o he hand, he e a e many composi e ma-
nu ac u ing echnologies based on hand lay-up. Al ho-
ugh hey migh seem ou -da ed, hey a e well sui ed
o manu ac u ing o la ge -scale pa s o small-se ies
p oduc ion in gene al.
CFRP is used in many b anches o enginee ing inc-
luding consume goods and spo s equipmen wi h he
main bene i s being weigh sa ings and igidi y. I may
come as a su p ise, ha in spo s op ics composi e
ma e ials ha e no ound a use ye . Bu compa ed o
i ea ms o example, (whe e ca bon ibe is some i-
mes used o make ails ocks o handgua ds), spo s
op ics de ices equi e di e en kinds o p ecision – in
some cases ole ances in mic ons.
Ca bon ibe composi e has densi y o a ound 1,7
kg/m3, which is simila alue o magnesium alloys and
lowe compa ed o aluminum alloys (2,7 kg/m3 o
6061). Howe e , CFRP has much highe s eng h. [2 ]
A compa ison o composi e ma e ials and me als is
no s aigh o wa d because o many a iables in de-
sign o composi es. Because o ha i is no possible
o p edic po en ial weigh -sa ings o CFRP binocu-
la s. I would be a ec ed by he numbe o laye s, hei
di ec ion and ype o ibe s and ma ix used. These pa-
ame e s would ha e o be ca e ully chosen and hen
es ed on a p o o ype piece.
This pape has been made in coope a ion wi h
Czech manu ac u e o op ical de ices (including
spo s op ics), Meop a - op ics, L d. In Meop a ca bon
ibe has been used as s uc u al ma e ial in many ap-
plica ions, bu spo s op ics ha e no been one o
hem ye . The pape ies o ackle he ques ion, whe-
a e CFRP could be used a all o de ices o spo s
op ics and analyses esul s o chosen manu ac u ing
echnology.
Binocula s ha e been chosen as a model de ice o
he ca bon ibe o be used on. A simpli ied p o o ype
was designed o de e mine i i would be possible o
manu ac u e binocula s-shaped body ou o ca bon
ibe a all. I lacks a ew key ea u es and componen s
o binocula s – o example, op ical p isms o ocusing
mechanism. Bu i wo ks as an exhibi ion piece and
p oo o concep in e ms o manu ac u ing.
The main pa o he p o o ype – ca bon ibe ube
was 3D scanned wi h GOM ATOS – op ical 3D scan-
ne . The p o o ype mold used o make he pa was
scanned as well. The esul s we e compa ed wi h he
CAD model and he de ia ions we e e alua ed.
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Design o he binocula s p o o ype
In he beginning, i was necessa y o examine he
possibili ies o manu ac u ing echnologies. Winding
is a echnology ha was conside ed a i s . Because o
i s na u e, i is mos ly sui able o pa s wi h ci cula
symme y. Al hough i is possible o manu ac u e
mo e complica ed shapes by winding, i o en b ings
many p oblems. [3] The main ad an age o winding is
p ecise con ol o ibe o ien a ion. I is c ucial o
pa s wi h high s i ness and s eng h in one di ec ion.
Howe e , o binocula s, all-a ound du abili y and e-
sis ance o impac s, ib a ions and o he dynamic lo-
ads, is mo e impo an . Žmindák [4] analyses he
e ec o ibe o ien a ion on mechanical p ope ies o
composi e ma e ials du ing dynamic loads.
In he end, p ep eg lay-up was selec ed as he ma-
nu ac u ing echnology o choice. I is mo e e sa ile
in e ms o a ainable shapes and because an au ocla e
was a ailable i was mo e cos -e ec i e. Ano he big
a gumen o using p ep eg lay-up is he inse wi h
p o usion, Fig. 1 and Fig. 7. I would be e y p oble-
ma ic, i possible a all, o wind ca bon ibe s a ound
he p o usion. Au ocla e cu ing allows o co-cu ing
he pa wi h he inse , which is e y con enien and
qui e a unique ea u e o his design. [5]
The binocula s p o o ype (Fig. 1) consis s o wo
CFRP ubes wi h 6061 aluminum alloy inse s. These
inse s a e glued in he ubes and hey p o ide in e -
ace o he objec i e and eyepiece o be moun ed. In
he middle o he ubes, he e is he co-cu ed polyca -
bona e inse (3D p in ed) wi h a cube-shaped p o u-
sion. The inside s uc u e o he ube can be seen in
Fig. 2. The p o usion ac s as an in e ace o he hinge
pa s o be moun ed and glued on o he ubes.
Fig. 1
Binocula s p o o ype
Fig. 2
S uc u e o he binocula s p o o ype
Manu ac u ing o he CFRP ube using
p o o ype mold
A p o o ype wo-piece nega i e mold om poly-
ca bona e (PC) was designed o manu ac u e he ube
[6]. The shape o he mold was compensa ed o ac-
coun o he mal expansion o he mold ha happens
a 120° C when he epoxy esin is cu ing.
The olume ic he mal expansion o mula was used:
∆𝑉𝑉

𝛽∆𝑡
(1)
𝛽3𝛼
(2)
Whe e:
∆V … Change in olume [m3],
V0 … Ini ial olume [m3],
β … Coe icien o olume ic expansion [K-1],
∆ … Change in empe a u e [K],
α … Coe icien o linea expansion [K-1].
The coe icien α o PC is 68,4 x 10-6 K-1 [7]. The
mold was 3D p in ed ou o polyca bona e using p o-
essional-g ade 3D p in e S a asys Fo us 360 L (Fig.
3). The su ace o he mold was hand inished wi h a
ine-g i sandpape . The alignmen o bo h pa s is
secu ed wi h wo cen e ing pins ha i in holes, which
we e inished wi h a eame . Gene al dimensions o
he mold can be seen in Fig. 4.
Fig. 3
Two-piece mold
Be o e lay-up sealan and elease-agen we e ap-
plied o hose su aces o he mold, which will be in
con ac wi h p ep egs. Fo he lay-up, ou laye s o
p ep egs om Del a P eg ha e been applied [8] – wo
shee s o GG380 DT121 and wo shee s o GG245
DT121, Table 1. Laye s o ca bon ha e been layed up
in bo h hal es o he mold o c ea e symme ic and
balanced lay-up, Figu e 5. Whe e he wo pa s o he
mold mee , he p ep egs we e o e lapped by 10 mm.
Se e al o he lay-up s yles we e es ed in he p ocess.
The pa was bagged, acuumed and cu ed in Ma oso
au oma ic au ocla e (diame e o he chambe 1 m,
leng h 2 m). The hea and p essu e cycles a e shown
in Fig. 6. A e manu ac u ing 10 pieces o ubes, he
3D p in ed mold was a he end o i s li e.
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Fig. 4
Mold dimension
Tab. 1
Lay-up scheme
Mold
245 g/m2 ±45°
380 g/m2 0°, 90°
380 g/m2 0°, 90°
245 g/m2 ±45°
Peel Ply
Sepa a ion laye
B ea he clo h
Vacuum bag
Fig. 5
P ocess o lay-up
A e cu ing, he ube needed o be inished. Faces
o he ube we e milled and he emains o pa ing line
we e sanded o . Milling composi e ma e ials equi es
special ools wi h di e en geome y o ools ha a e
used o machining me als. Because only 10 p o o ype
ubes we e made, egula ools ha e been used. Be-
cause o ha , ool wea was apid and he su ace i-
nish wasn' sa is ac o y. The pa needed o be hand-
inished. In p oduc ion on a g ea e scale, p ope ools
and op imized cu ing speeds would ha e o be used.
[9]
Fig. 6
Au ocla e p essu e and empe a u e cycle
Fig. 7
Finished ube wi h inse s glued in place
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The las s ep o he manu ac u ing p ocess was
gluing he h eaded inse s (Fig. 7). Because he main
pu pose o his p o o ype was being displayed as an
exhibi ion piece, achie ing he concen ici y o he in-
se s was no necessa y. Howe e , his would be a c u-
cial pa ame e in eal, p ope ly wo king binocula s.
Concen ici y could be secu ed wi h alignmen jig o
by u ning he inse s a e gluing.
3.1 The p ocess o 3D scanning
The mold and he ca bon ibe ube we e measu ed
using an op ical 3D scanne GOM ATOS. The pa s
we e sp ayed wi h an i-gla e sp ay. I lea es empo a y
ma whi e inish. Sel -adhesi e e e ence poin s we e
placed on he su ace o he pa . [10][11].
Fig. 8
3D scanning o he ube
To ensu e e en scanning, he pa s we e placed
on o a p og ammed u n able du ing scanning (Fig. 8
andFig. 9). Resul o he measu emen s was a polygo-
nal mesh ha was expo ed as a STL ile.
Fig. 9
3D scanning o he mold
3.2 E alua ion o da a
The measu ed da a was e alua ed using so wa e:
GOM Inspec and Mic oso Excel. In GOM Inspec
a .STL ile was impo ed. The alignmen o he ac ual
da a wi h he CAD model was made wi h Local Bes
Fi on he conical pa o he ube. Acco ding o equi-
emen s by Meop a o ge a comple e opog aphy o
he mold, c oss-sec ions wi h in e als o 10 mm we e
c ea ed ac oss he pa in GOM Inspec . In each
c oss-sec ion measu emen s e e y 5 deg ees we e a-
ken (Fig. 10). The analyzed mold in he GOM Inspec
en i onmen can be seen in Fig. 11, esul alues
discussed in chap e 4.
Fig. 10
Measu ed c oss-sec ions and poin s o he mold
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Fig. 11
Di e ence epo mold wi h CAD model
Fo he ube, he same me hod was applied wi h
one di e ence - he measu emen s we e aken a ound
he ull ci cum e ence o he c oss-sec ions (Fig. 12).
The c oss-sec ions o he pa and he mold align wi h
each o he . The ube in he GOM Inspec en i on-
men can be seen in Fig. 13.
Fig. 12
Measu ed c oss-sec ions and poin s o he ube

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Fig. 13
Di e ence epo ca bon ibe ube wi h CAD model
Resul s
In he ollowing chap e , he esul s a e analysed
and discussed.
4.1 Mold
Only a small sample o measu ed poin s is eco -
ded in able 2. Fig. shows he chosen coo dina e sys-
em in e ms o he angle alue o he poin s in each
c oss-sec ion. Poin s wi h ± 90° angle we e excluded
om he sample because o he cham e on he edge
o he mold. The a i hme ic mean c oss-sec ion is
calcula ed om all measu ed c oss-sec ions, no only
he ones eco ded in able 2.
Fig. 14
Dimensioning o measu ed poin s on he mold
Tab. 2
De ia ions o poin s o he mold
Angle [ ° ]
De ia ion [ mm ] o a ious c oss-sec ion
25 mm 65 mm 95 mm 125 mm 155 mm A i hme ic mean
c oss-sec ion
-85 -0.20 -0.31 -0.28 -0.31 -0.38 -0.294
-80 -0.16 -0.27 -0.21 -0.26 -0.33 -0.246
-75 -0.15 -0.21 -0.15 -0.20 -0.28 -0.198
-70 -0.13 -0.18 -0.10 -0.14 -0.24 -0.162
-65 -0.09 -0.15 -0.05 -0.10 -0.23 -0.130
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
55 -0.02 -0.07 -0.09 -0.03 -0.12 -0.076
60 -0.06 -0.11 -0.12 -0.10 -0.20 -0.124
65 -0.07 -0.16 -0.16 -0.19 -0.31 -0.178
70 -0.10 -0.20 -0.20 -0.26 -0.39 -0.226
75 -0.13 -0.22 -0.26 -0.31 -0.47 -0.269
80 -0.15 -0.25 -0.31 -0.39 -0.55 -0.317
85 -0.20 -0.28 -0.37 -0.43 -0.62 -0.370
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Fig. 15 plo s alues o de ia ions om able 2.
La ge de ia ions o alues abo e ± 50 ° can be ob-
se ed. I sugges s signi ican wa page o he mold in
he a ea nea he pa ing line. The mold had endency
o close in on i sel . Because he 3D scanning was
ca ied ou a e manu ac u ing 10 CFRP pa s in he
mold, i is no clea whe he he wa page happened
di ec ly a e 3D p in ing o was a esul o hea cycles
in he au ocla e.
The wa page o “C-shaped” pa s is common due
o s ess dis ibu ion in hese pa s. As a esul , mea-
su ed cylind ici y on he wide end o he mold (Fig.
11) is 0.24 mm.
Fig. 15
De ia ion o measu ed poin s in di e en sec ions
As can be obse ed on he “A e age c oss-
sec ion” - alues he ca i y is on a e age smalle han
he nominal alue om CAD da a (0 on he y-axis in
he plo ). This is due o olume compensa ion o he
shape o he mold. which was ca ied ou based on he
au ocla e hea cycle (Fig. 6).
4.2 Tube
The ube was measu ed in a simila way o he
mold (Fig. 16) – sample da a o da a is eco ded in a-
ble 3.
Fig. 16
Dimensioning o measu ed poin s on he ube
Tab. 3
De ia ions o poin s o he ube
Angle [ ° ]
De ia ion [ mm ] o a ious c oss-sec ion
35 mm 65 mm 95 mm 125 mm 145 mm A i hme ic mean
c oss-sec ion
-85 0.07 -0.01 0.04 -0.04 -0.19 0.000
-80 0.08 0.03 0.11 0.02 -0.14 0.038
-75 0.08 0.07 0.16 0.08 -0.08 0.071
-70 0.09 0.10 0.2 0.12 -0.05 0.095
-65 0.12 0.12 0.25 0.16 -0.02 0.130
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
55 0.11 0.08 0.10 0.25 0.26 0.154
60 0.10 0.07 0.06 0.21 0.20 0.127
65 0.10 0.05 0.02 0.16 0.12 0.087
70 0.10 0.04 -0.02 0.10 0.06 0.056
75 0.11 0.02 -0.07 0.05 0.00 0.032
80 0.11 -0.02 -0.06 0.00 -0.08 0.006
85 0.11 -0.04 0.00 -0.01 -0.12 0.002
In Fig. 17, da a om able 2 a e plo ed. As expec-
ed, he shape o he lines closely esembles he su ace
o he mold. This esul sugges s, ha he quali y o
he ube would be highly imp o ed i me al machined
mold had been used. Di ec compa ison o a e age
c oss-sec ions o he 3D p in ed p o o ype mold and
he ube is shown in Fig 18. Dha al and Pa el p esen
a compa ison o pa manu ac u ed by in usion and
p ep eg lay-up in hei pape [12]. In hei case, he
p ecision o he in used pa was g ea e han he pa
made om p ep egs.
The e is no appa en sp ing-back o he pa due
o i s ubula shape. Pape by Dha al and Gajja [13]
deals wi h sp ing-back o “L-shaped” pa s.
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As he plo s show, he a e age c oss-sec ion o he
ube has de ia ions consis en ly abo e he nominal a-
lue o he CAD da a. This sugges s, ha he he mal
compensa ion men ioned in Chap e 3 does no di-
ec ly co espond wi h he eal si ua ion. The ac ha
he de ia ion o he ube is g ea e , han he de ia ion
o he mold caused di icul y when emo ing he pa
om he mold.
Fig. 17
De ia ion o measu ed poin s in di e en sec ions
Fig. 18
Compa ison o de ia ions o a e age c oss-sec ions o
he mold and ube
The Following esea ch
Mo e esea ch needs o ollow up in o de o
examine he use o CFRP in he ield o spo s op ics
in a comp ehensi e way.
E en mo e impo an han he ini ial p ecision o
manu ac u ing is he he mal s abili y o he pa i sel
and he bonds wi h o he componen s. I is impo an
ha adhesi e ha is used can wi hs and clima ic con-
di ions a which binocula s a e es ed. Because o ha
empe a u e s abili y es o adhesi e join s es s ha e
been designed.
Fig. 19
Samples on he alignmen jig
Fig. 20
Adhesi e es sample
Measu ed samples consis o wo me al cylinde s
ha a e glued oge he on a jig o ensu e concen ici y
Fig. 19 and Fig. 21. The gap ha is illed wi h glue is 3
mm wide. Because o ha , he long- e m concen ici y
o he inne and ou e ube is de e mined by he s abi-
li y o he glue. In he u u e, a ious sizes o he gap
will be es ed. When he adhesi e is ully cu ed con-
cen ici y o he ubes is measu ed on CMM Zeiss
Con u a G2 o ge a e e ence Fig. 21.
Fig. 21
Measu emen o he adhesi e es sample
Tempe a u e es s ollow. The samples will be pla-
ced in a clima ic chambe ( ange o empe a u es will
be es ed). Concen ici y is measu ed a e e e y es .
The i s se o es s has he samples s anding on hei
aces. Tes s in he ho izon al posi ion will ollow o
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ge esul s wi h di e en ypes o s ess on he glue.
The es s a e s ill in p og ess and he esul s a e no
eady ye .
Ca e ul choice o manu ac u ing echnology o
he ubula CFRP pa would be ano he poin o in-
e es in u u e wo k. This p oblem needs o be
ackled om mul iple poin s o iew. One o hem is
o examine which echnology b ings pa s wi h he
bes mechanical p ope ies ega ding s i ness and
s eng h. Kulha ý deals wi h his p oblema ic in his
pape s, in his wo k he compa es expe imen s wi h nu-
me ical simula ions as well as compe ing di e en ma-
nu ac u ing echnologies [14][15]. Ano he p oblem is
he p ecision and s abili y o CFRP pa s. The e is no
much esea ch ha has been made a his momen , he
impac o manu ac u ing echnology on p ecision and
s abili y needs o be quan i ied by expe imen s made
wi h a la ge sample o pa s.
Conclusion
The main pu pose o his pape was o design and
manu ac u e a p o o ype sample using a CFRP manu-
ac u ing echnology. I se ed as a p oo o concep
in e ms o manu ac u ing a binocula s-like body using
CFRP. The wo-piece p o o ype mold and he CFRP
ube we e 3D scanned using op ical 3D scanne GOM
ATOS. The measu ed da a we e e alua ed and com-
pa ed o he nominal CAD model.
As expec ed, he p ecision o he mold s ongly
a ec s he inal p ecision o he manu ac u ed pa .
The wo-piece nega i e p o o ype mold men ioned in
his pape , which was made om polyca bona e,
showed a wa page de o ma ion and as a esul , he
ube pa was na owe nea he pa ing line. As ex-
pec ed, he opog aphy o he su ace o he inal pa
closely esembles he opog aphy o he su ace o he
mold.
The a e age de ia ion o he mold is nega i e –
meaning ha he mold is smalle han expec ed. I is
caused by ela i ely high coe icien o he mal ex-
pansion o polyca bona e. Du ing he condi ions in
au ocla e – 6 ba and 120 °C he ube expanded and
a e cooling o he oom empe a u e sh inked. A e
cu ing he pa was di icul o emo e om he mold
as a esul o small cu e sh inkage o he epoxy esin.
These impe ec ions a e accep able when conside-
ed he ma e ial and echnology o he manu ac u ing
o he mold. FDM is p ima ily an al e na i e echno-
logy o p o o ype p oduc ion in he case o molds.
Men ioned p oblems would be elimina ed i machined
me al mold had been used.
As men ioned in he chap e “The ollowing e-
sea ch” he he mal s abili y o pa s and join s may be
mo e c ucial, he e o e i will be he ocus o u u e
es s.
Acknowledgemen
This esea ch wo k was suppo ed by he B no
Uni e si y o Technology, Facul y o Mechanical
Enginee ing, Spe-ci ic esea ch 2019, wi h he
g an " Resea ch o pe spec i e p oduc ion ech-
nologies ", FSI-S-19-6014.
Re e ences
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