Introduction: Hemp Composite Shell

I wanted a small shell for a wearable project I am working on. I decided to make it with hemp fiber and bio-derived epoxy resin rather than fiberglass and polyester resin. I find these materials more user friendly in that they don't pose as great an inhalation hazard, both in terms of particulates and fumes. Furthermore, bio-derived epoxy resin has no ozone-depleting volatile organic compounds, unlike polyester. Hemp and other bast fibers can be grown organically with no pesticides and little water, in contrast to the large carbon foot print of glass fiber production. There is a trade off in strength properties and service life, but natural fiber composites are suitable for many demanding applications.

Vacuum bagging hemp fiber composites is a fairly complex, technical process - I don't have good photos of all of the steps involved, but the following will give the reader some idea of how it's done.

Step 1: Original Form Work

I made a male mold out of an abalone shell covered with epoxy clay and sanded smooth. The result was this pleasing aerodynamic form. I liked the idea of "finding" a form in nature rather than designing it.The grey is the epoxy clay, the red is the actual shell. The plywood has a grid cut on it with a table saw, to enable air flow during the vacuum bagging process.

Step 2: Vacuum Formed Styrene Molds

These enable a relatively finished surface on both sides of the laminate right out of the mold. They were made over the shell on a small vacuum former. Notice they are labeled 1 and 3 - I formed 3 sheets of styrene on top of each other, and removed the middle one to make room for the bio-derived epoxy resin saturated hemp cloth. The holes are for air flow.

Step 3: Vacuum Bagging Process

Here we see the wet laminate, sandwiched between the vacuum formed molds on top of the shell, under vacuum while it cures.

Step 4: The Resulting Shell

As you can see, both sides are relatively smooth right out of the mold.The few small air bubbles can be sanded out, and the shell gloss coated later in the process.

Comments

author
Triclaw made it! (author)2014-08-02

your going to wear this? is it for under a hat?

author
BARKing made it! (author)BARKing2014-08-02

More likely two of them under the shirt ;)

author
spunk made it! (author)spunk2014-08-03

I have trouble to understand in which way these comments are positive and constructive.

But I really like the instructable. Thanks for sharing!

author
Triclaw made it! (author)Triclaw2014-08-04

i like it to but im curious about what it is for the author said it was for a wearable project ??

author
spunk made it! (author)spunk2014-08-05

Thanks for the response and clarification.

author
Triclaw made it! (author)Triclaw2014-08-05

welcome, I wish the author would do the same

author
mmarfin made it! (author)mmarfin2016-09-14

I'm reviving my engaement with this instructable, and will probably be
posting a new instructable about what I'm doing with it soon.

author
mmarfin made it! (author)mmarfin2016-09-14

I'm reviving my engaement with this instructable, and will probably be
posting a new instructable about what I'm doing with it soon.

author
mmarfin made it! (author)mmarfin2014-08-05

No, more like a shoulder pack. I'll post again when I finish a prototype.

author
Triclaw made it! (author)Triclaw2014-08-05

ok that makes sence cant wait to see the finished project

author
mmarfin made it! (author)mmarfin2016-09-14

I'm reviving my engaement with this instructable, and will probably be
posting a new instructable about what I'm doing with it soon.

author
Triclaw made it! (author)Triclaw2014-08-03

i see

author
emile.mac.7 made it! (author)2015-03-13

Hello! What brand and where do you buy bio-derived epoxy resin?

Thit is the crucial info missing from this article!
Kudos for the tutorial, i just need to find a source of this resin..

Thanks!

author
mmarfin made it! (author)mmarfin2016-09-14

I'm reviving my engaement with this instructable, and will probably be posting a new instructable about what I'm doing with it soon. Here is the bio-derived resin info:

https://entropyresins.com/product/super-sap-clr-clear-epoxy-resin/

author
savannahm11 made it! (author)2015-04-14

hi there! what brand and where do you buy bio-derived expoxy resin?

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