Any composites nerds on here?
If i were to 3d print aero bars, with a center channel to put a carbon or steel rod for easy rigidity, and then skinned the plastic bars with carbon, how many layers (let's say by default i'd use the 200g/m2 version that seems ubiquitous) would i need to add to have something really strong? I've 3d printed stuff for the bike before, and it was fine, until it just disintegrated in a split second w/o warning, and i'd rather not crash.
Also, if i want to go disco disco and use different weaves (some look really sexy), how would that affect the strength / # layers i'd need?
The price of commerical aero extensions is just insulting to common sense, and i know 1st hand how much more comfortable it is to rest on forearms rather than just elbows, so i'm thinking of ordering a bunch of materials to play around this winter. I have a 3d printer so the prototyping, shaping and what not will just cost me a few rolls of plastic. Foam's foam.