What is Carbon Fiber?

Manufacturing of Carbon Fiber requires a polymer precursor material that can have an effect on the quality of the fibers produced. These precursor materials are expensive, the chemical and mechanical process to turn them into carbon is time consuming and often, the carbon yields are low. Fibers are produced from a polymer such as Polyacrylonitrile (PAN), rayon, or petroleum pitch are then spun into filament yarns, using chemical and mechanical processes to initially align the polymer molecules in a way to enhance the final physical properties of the completed fibers. These compositions are then mechanically processed using drawing and spinning method, after which the polymer filament yarns are heated to drive off non-carbon atoms (carbonization), producing the final fiber tow.

Why Carbon Fiber?

It is frequently supplied in the form of a continuous tow wound onto a reel. Several thousand fibers are bundled together to form a tow, which may be used by itself or woven into a fabric. Composite materials, such as carbon fiber reinforced plastics are highly versatile and efficient materials, driving innovation in various markets from automotive, aerospace to healthcare. They outperform traditional materials such as steel, aluminium, wood, or plastic, and enable the fabrication of high-performance lightweight products. Automotive Parts made from Carbon fibers are nearly five-times stronger than steel, three times lighter, twice as stiff and have better yield strength. This makes them particularly interesting to developers of high performance vehicles, who use the composite material as an alternative to traditional steel construction.

It made way for automotive manufacturers to build better light weight vehicles to improve performance & safety. A distinctive and beautiful look as well as excellent strength, stiffness, durability and fatigue resistance have made it the material of choice for wide range of industries.

Process

We manufacture our parts in various ways. The most common are Hand Lamination, Vacuum Infusion, and Autoclave.

Hand Lamination

Hand Lamination process is done by cutting fabric to shape and laid on to the original part carefully and accurately to exact OEM fitment. This is the most labor intensive, time consuming and expertise process, however also the most accurate of parts where perfect fitment is required. All our Carbon Fiber car parts manufactured with skinning is done for making Carbon Fiber Interiors, Carbon Fiber Steering Wheel, Mirror Covers etc. All our parts are then applied with specialized coating for additional UV protection.

Autoclave

Pre-impregnated materials, or prepregs, are carbon-reinforced fabrics or fibers into which a pre-catalyzed resin system has been impregnated by a machine.

High quality parts are produced with precise control and optimal performance by using prepreg resins. The resin systems have been pre-catalyzed, so curing the resins requires heat only. This allows the build-up of parts in autoclave, which ensures the best results in terms of dispensability, penetration and chemical resistance of the resulting laminate. This process is used by Formula 1 & Supercar manufacturers to build high-quality lightweight parts.

Resin Infusion

Vacuum-assisted resin infusion is a resin transfer molding process that employs vacuum to draw the liquid resin into the pores of the dry reinforcement materials, rather than forcing it. The result is very low void content and excellent mechanical properties due to the high fiber content. Fiber content is determined by fiber architecture and pressure. Resin infusion can also be applied to thermoset prepregs and tapes as well as dry fabric, aramid and glass fabrics, ceramic fibers and other reinforcements. Benefits are better cosmetic finishes and variation in part thickness, plus faster cycle times for lower cost. Tools can be aluminum, steel or composite. This process is mainly used to manufacture Carbon Fiber Car Parts that are cost effective and low volume while having highest strength and lightweight characteristics.