Thank you! I will do my best to spread the word so this technique is not lost to history. I've been hoping you would reveal it since last year, but only just now found this page since you never updated the original metal bone project.

So it's not simply metal foam, but metal matrix carbon fiber. Very interesting, particularly since it provides a heat-tolerant alternative to epoxy matrix. Perhaps this is the solution Elon needed for his Starship, when carbon ended up needing so much heat shielding that it lost most of its weight advantage over steel.

Much work to be done measuring stiffness and strength and density to see how things made this way compare to solid aluminum and traditional carbon fiber with epoxy. I'd also like to see if I can include chunks of solid metal in the plating substrate to create areas for post-process machining. Not sure if they will bond strongly enough.

The biggest problem I can think of is galvanic corrosion. If the metal is abraded, revealing some carbon surfaces, it will likely start eating away at itself if there's much moisture in the air. Titanium would be less reactive with carbon, but seems difficult to electroplate from quick research. If it is an insurmountable problem, there are still options such as using metal wool as the fiber base. And of course keeping the object painted or periodically re-plating would help to retard the corrosion.

New idea! In addition to using the metal composites directly, it will also make an excellent core material for traditional epoxy carbon fiber. The metal will be fully encased so it can't corrode, and you will surely get the super strength of continuous carbon fiber, and will have great versatility in creating the core with complex geometry and variable density, including hollow spaces that you can't do with foam core since it would collapse under vacuum pressure.

I understand most of the process, but it seems to me that the most difficult part is the outer casing to fill in the carbon fibres.

How did you get the green casing in the beginning?

It was 3d-printed on a resin printer. Casing is only for shape, you can make it from anything non-conductive. If you don't want to make casing, you could try making shapes from carbon-felt.

It's the easiest part. You just print it (DLP printer). However, it's only one of a few ways.

Ive been experimenting with same thing 6 months ago.

Really? Please, show your work! I am very interested. Thank you!

It failed, weak power supply. Definetly gonna try it in future after seing your results.

Did you removed coating from carbon fiber?

What kind of coating?

Usually thin layer of epoxy or polyester etc., the process is called sizing.

Fibers from recycling (after pyrolysis) were clean but I had problems with a new roving.

Wow, I've thought you will never tell anybody how it's done. Nice results, thank you!

> In what area and how would you use this method? Thank you in advance for your help!

I'll try to make better heat exchangers for my heat engine.

"I've thought you will never tell anybody how it's done."

Me too... ;)

Things like this don't happen often, and I can't get it all. However, from the beginning I was planning to release this information, it is too serious matter, it has to serve all people.