Most teams in composites build parts out of carbon fiber and kevlar. These materials have an extremely high strength to weight ratio and can be molded into unique shapes, which makes them desirable for creating lightweight yet durable custom-shaped parts. To make a part out of carbon fiber, this general process is followed:

1. CNC a “plug” out of foam.
2. Sand the plug really nicely.
3. Make a mold (out of orange gelcoat and fiberglass) from that plug.
   
4. Make a “layup” using the mold surface. (Lay carbon fiber and epoxy, then let it cure using pressure or heat.) 

*it should be noted that some teams use different chemicals than others. We’ve done our best to mark which teams use which chemicals