Carbon Fiber Part Manufacturing and Processing

2025-09-09 09:57:41

Carbon fiber composites, with their exceptional strength-to-weight ratio and design freedom, are reshaping the manufacturing landscape of modern industrial components. This article will delve into the six core manufacturing steps of carbon fiber components, revealing the secrets to the creation of high-end composite products.

1. Prepreg Cutting: Precision Begins

Carbon fiber component manufacturing typically begins with prepreg. Prepregs are divided into two types: thermoset and thermoplastic. Thermoset prepregs require low-temperature storage and must be removed from cold storage and refrigerated before use; thermoplastic prepregs, on the other hand, can be used directly. Of the two types of carbon fiber, thermoset is the most widely used. This article focuses on thermoset carbon fiber products. Based on the design drawings, these prepregs are cut using a cutting system to precisely tailor the desired shape and size, with tolerances within ±0.1mm. This ensures the contour accuracy of complex components and prepares them for subsequent processing.

2. Layup Design: Meticulously Crafted Layer by Layer

Each component has its own unique tooling setup, which determines how the prepreg is laid up. The layup design is crucial as it directly impacts the performance of the final product. Based on the actual performance requirements of the product, engineers use finite element analysis to reverse engineer the layup plan, determining the orientation and number of layers to ensure structural strength and stability. This process is time-consuming, but every detail must be rigorously controlled to ensure the high quality of the final product. Gradient layup technology is implemented in key load-bearing areas, allowing local layer counts to reach over 80, significantly improving structural load-bearing efficiency.

3. Molding Process: Creating the Perfect Form

Molding is a key step in transforming prepreg into a finished component. Common molding methods include high-temperature compression molding and autoclave molding. The choice depends on the specific requirements of the component, such as structural complexity, performance standards, and cost budget. High-temperature compression molding is more suitable for small, complex components, while autoclave molding is more suitable for large, monolithic components. Through these molding processes, the initial carbon fiber component blank is created, but this is only the first step.

4. Precision Machining: Striving for Excellence

After forming, the blank requires further finishing to meet final design requirements. This step includes CNC cutting and drilling to ensure component accuracy and assembly requirements. Due to the unique properties of carbon fiber, the machining process requires careful attention to tool selection and adjustment of operating parameters to avoid problems such as fiber pullout and matrix separation. For example, diamond-coated tools are used with minimal lubrication technology, spindle speeds reach 20,000 rpm, and feed rates are optimized to 800 mm/min. This achieves machining accuracy of IT7 and a surface roughness of Ra ≤ 0.8 μm.

5. Surface Treatment: Improving Appearance and Functionality

After finishing, the carbon fiber parts undergo surface treatment. Most products produced by Zhishang New Materials undergo a three-stage coating process, which we call a three-stage coating system. First, the parts are cleaned and the release agent removed. Then, a primer is applied to improve adhesion. A mid-layer of color paint or functional requirements are applied. For example, conductive/wear-resistant carbon fiber pole piece rollers are required in this step. Finally, a third layer of topcoat is applied to enhance the product's aesthetics. For example, the surface of a carbon fiber robot arm must achieve a mirror-like finish, which is achieved during the third layer of topcoat.

6. Quality Inspection: Rigorous Quality Control

This step involves rigorous quality inspection of finished products. Methods include industrial CT scanning to detect internal defects, three-dimensional coordinate measurement of key dimensions, and fatigue testing to simulate service conditions to verify dimensional accuracy, appearance quality, and actual performance. Only samples that pass all inspections are approved for mass production. On-site testing is also essential, especially during the proofing phase, to ensure that each component meets the end-user's requirements.

As industrial development accelerates, carbon fiber components are moving towards greater integration and functionality. Only by establishing a collaborative innovation platform for materials, processes, and equipment and achieving breakthroughs in key technologies such as one-step molding of complex components and intelligent online detection can we better promote the application advantages of carbon fiber industrial parts and inject new momentum into high-end equipment manufacturing.