We continue to refine and update our new in-house composite parts for the T3.
The carbon fiber over molded battens are now made with one ply of unidirectional carbon fiber and one ply of 2×2 twill, woven carbon fiber. Although we were quite pleased with the greatly improved stiffness-to-weight of the original 2-ply uni configuration, there were concerns with durability. Because all the fibers were running longitudinally, should a crack occur, the fibers would splinter off from the underlying batten. The woven outer ply on the newer configuration should help prevent this, although sacrificing a small amount of stiffness and adding a tiny bit more weight. The 2×2 twill pattern also improved the cosmetic look of the battens.
The ACLER – Advanced Composite Leading Edge Reinforcements have also been improved. We are now using one ply of lightweight Kevlar and one, smaller ply of 2×2 3K twill carbon fiber. Again the reason for this change is primarily durability. The original design used a single ply of 1×1 6K carbon fiber. This provided the correct stiffness while still allowing enough flexibility to conform to the compound curve of the leading edge, but carbon fiber is inherently brittle and prone to cracking. Kevlar, on the other hand, is much more durable but not as stiff. Hence the need for one ply of each. By using a bit less carbon then Kevlar, we are able to achieve an even better balance between stiffness where you need it and flexibility where you need it.
These parts have been a fun a rewarding project, especially considering the overwhelmingly positive feedback and success of the T3. They are in production and available now, standard on the T3 Team edition and as upgrades on lower trim models.