Manufacturing Process for Final Design:
Handle: The handle will be made by using a two part mold (displayed in the picture below). Aquacore will be used to obtain a hollowed out center for the part. Carbon fiber will be laid up with an epoxy system around the aquacore. The part will then be placed in a press to close the two halves of the molds.
Shaft and Head Insert: The shaft and head insert will be table rolled using a carbon fiber/epoxy prepreg. The tooling for the table rolled shaft is displayed below.
Shaft Pins: The shaft pins will be made out of zinc coated steel and will be purchased from an outside manufacturer.
Head: The head of the shovel will be vacuum assisted resin transfer molded (VARTM)