Great thread. Just what I tried to do, so I can go through some learnings and hopefully help you
1) I designed the wing (also in Fusion using parameters from another software (3DFoil)) and offset it in order to accommodate the CF skin. This part worked well (I'll discuss design itself in the other thread)
2) I printed the wing in 5 parts (the stab in 2). Since I'm using an FDM printer and i wanted a good top and bottom surface, as well as align the layers along the span of the wing, I printed the parts standing. This also worked relatively well, in fact I could print all 5 parts for the front wing in one go.
3) Here's where the trouble began. I place 3 layers of weave, vacuum bagged it. There were a lot of creases and small imperfections. So now I had to sand it. I used a Tyvek suit, mask etc, and by the time I was done the suit (and my garage) were all covered in CF dust. No good. But I had a reasonably shaped wing.
4) I felt that there was too much flex in the wing if you support it on the edges and push in the center. So I decided to lay 2 layers of uni. Same process, and here's where I stopped, before sanding. There is still flex, but prob good enough. I think the wing is thicker also than intended. The surface sucks, so I have to sand again, and I certainly wont get that nice CF look (not that it matters but would be nice).
Other things
- initially I wanted to print in PLA. ABS warps too much especially for such an elongated shape. I knew beforehand that adhesion to epoxy would be an issue no matter what plastic I used. So I tried PLA, and since it was brittle, I abandoned it in favor of PETG, which instead of breaking it bends. So that's what I used instead.
- the stab worked VERY well. That is done and rigid enough.
- i used Bondo to repair the small imperfections coming out of the printer. the alignment wasn't perfect at the junction for example.
coming out of the printer
before
before CF mounted on LF foil
this is after the uni
stab