Production of Composite Parts with Carbon Fiber
A combination of strength, lightness, and innovation in industrial design
In the world of advanced engineering, selecting the right material is one of the most critical factors in designing and producing industrial components . Carbon fiber
, as one of the primary reinforcements in polymer composites, has gained widespread attention across various industries due to its high strength, low weight , excellent
fatigue resistance, and favorable thermal and chemical properties.
Composite parts made with carbon fiber have brought about a major transformation in modern technologies—from aircraft and racing cars to professional bicycles,
medical equipment,aerospace energy, and even fashion and industrial design . This article explores the characteristics , production processes , applications , challenges
, and future of carbon fiber composite parts.
Outstanding Properties of Carbon Fiber
Carbon fiber is made of extremely thin carbon filaments,usually less than 10 microns in diameter. These fibers are typically produced from precursors like polyacrylonitrile
(PAN) through specific thermal and chemical processes.
Key Properties:
Very high strength-to-weight ratio (5 to 7 times that of steel at only one-fifth the weight)
Excellent tensile strength (over 3000 MPa)
High corrosion and fatigue resistance
High thermal stability
Flexible design and forming capability in composite structures
Controllable electrical and thermal conductivity
Combining Carbon Fiber with Resin to Produce Composites
Carbon fiber alone is not usable and must be embedded in a matrix (usually polymeric) to become a strong and workable component.
Commonly used resins:
Epoxy Resin – Best mechanical performance, high adhesion
Vinyl Ester Resin – Corrosion-resistant, more affordable than epoxy
Polyester Resin – Economical but with lower mechanical properties
The matrix transfers loads between fibers, protects against moisture and impact, and maintains structural integrity.
Production Processes for Carbon Fiber Composite Parts
The production method depends on the type of part, production volume, desired precision, and cost.
Hand Lay-Up
A simple and low-cost method for low-volume production
Fibers are laid onto a mold and resin is applied
Compaction is done using vacuum or pressure
Vacuum Bagging / Infusion
Enhances quality using vacuum pumps to remove air bubbles and increase density
Suitable for lightweight yet strong parts
Resin Transfer Molding (RTM)
Resin is injected into a closed mold containing dry fibers
Allows precise control over thickness and surface quality
Filament Winding
Used for cylindrical parts like high-pressure tanks, pipes, and booms
Fibers are wound helically around a mold and impregnated with resin
Autoclave Molding (High-Pressure Oven)
For high-precision, high-strength parts (used in aerospace)
Prepregs are molded and cured at high temperature and pressure
Pultrusion
Continuous production of composite profiles with constant cross-sections
Suitable for beams, angles, and construction profiles
Industrial Applications of Carbon Fiber Composite Parts
Aerospace
Aircraft fuselage, tail, wings, interior parts, and sensor equipment
Reduced weight = lower fuel consumption and extended flight range
Automotive and Transportation
Hoods, bumpers, rims, chassis for race or electric cars
Enhanced acceleration, lower fuel consumption, improved safety
Energy
Large wind turbine blades, frames, and electronic housings
Lightweight with resistance to harsh environmental conditions
Medical
Lightweight prosthetics, sports wheelchairs, non-magnetic imaging equipment
Challenges and Limitations
High cost of raw materials: Especially aerospace-grade PAN carbon fiber is very expensive.
Need for expertise and advanced equipment: Accurate production requires mold-making, vacuum systems, autoclaves, and non-destructive testing.
Low recyclability: Thermoset composites cannot be melted or mechanically recycled after curing. Research is ongoing in chemical recycling methods.
High electrical conductivity: In applications like electronics, separate insulation is required.
Future Trends in Carbon Composite Manufacturing
Lowering costs by producing cheaper PAN fibers or using bio-based carbon fibers
Increasing use of prepregs for more controlled production quality
Development of automated fiber placement (AFP) robots
Advanced recycling with low-energy chemical methods
Integration of nanoparticles to improve flame resistance, UV protection, and electrical performance
Conclusion
Carbon fiber composite parts represent the intersection of strength, lightness, and technical advancement. Despite their technical and economic challenges, their significant
benefits have made them a strategic choice in modern industrial product design . Advancing production technologies and investing in domestic equipment and material
localization can pave the way for widespread adoption of these materials in Iranian industry.
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