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Forged Carbon

Material Name

Manufacturer

MC 8224-01

PROCESS

A simple, expedited molding process to create lightweight forged carbon-fiber composite parts with specific design and color features. The molded parts are composed of 35%–69% carbon fibers, 30%–60% epoxy, and 1%–5% toner (resin + colorants). The standard woven carbon fiber composites are typically made layer by layer and infused with epoxy or in premade sheets, which are baked to a form in an autoclave. The process is expensive and time consuming, and also makes it difficult to form complex shapes. In the case of forged carbon composites, a mixture of chopped carbon fibers and epoxy is used to form parts in a mold, cured at high temperature and pressure, followed by painting and polishing for a high-quality surface finish. The result is lightweight (1.4 g/cm2–1.8 g/cm2, 45.9 oz/ft2–59 oz/ft2) carbon-fiber-reinforced parts with unique textures and patterns in different colors, which can be achieved via different steps and can be made quickly at a reduced cost. The random arrangement of the chopped fibers, higher fiber volume, and the improved molding process results in a significant improvement in tensile strength (3500 MPa, 507.6 ksi) and load-carrying capacity while reducing the product weight and variability over standard carbon fiber molded compounds, making them ideal for automotive and sports goods. Due to its chopped nature, it can be molded into much more complex geometries than traditional carbon fiber composites, and is suitable to make three-dimensional parts and parts that feature complex details, such as thickness transitions, holes, compound curvature, etc. Available in 2 patterns (orderly and disorderly) in over 10 different colors (black, gray, red, blue, silver, white) in different widths. It is possible to customize the size, thickness, pattern, color, and finish. Typical sizes range from 10 mm to 500 mm (0.39 in to 19.7 in) with 1 mm (0.039 in) to several mm thickness. Applications are for automobile interior parts, audio cases, sports goods, glass frames, smartphone back covers, and accessories.
Manufacturer

Manufacturer

PROCESSING + APPLICATIONS
PROCESSING
  • Additive Manufacturing No
  • Blow Molding No
  • Casting No
  • Cold Pressing / Deep Drawing No
  • Die cutting No
  • Extrusion No
  • Injection Molding No
  • Lamination No
  • Metal Working Tools No
  • Printing No
  • Rotomolding No
  • Stitching No
  • Thermoforming/Compression Molding No
  • Welding No
  • Wood Working Tools No
APPLICATIONS
  • Accessories
  • Automotive Interior
  • Consumer Electronics Casings
  • Sports Equipment
CUSTOMIZATION
  • Color
  • Size
  • Thickness
  • Texture
  • Pattern
  • Finish
Properties
PERFORMANCE PROPERTIES
  • Acoustics
    Sound Diffusing
  • Chemical Resistance
    Medium
  • Colorfastness
    High
  • Fire resistance
    Medium
  • Impact Resistance
    Good
  • Outdoor use
    No
  • Reflectivity
    Light Absorbing
  • Scratch resistance
    Medium
  • Stain Resistance
    High
  • Tear Resistance
    N/A
  • Thermal Conductivity
    Low
  • Usage Temperature
    Low
  • UV Resistance
    N/A
  • Water Resistance
    High
  • Wear Resistance
    Medium
PHYSICAL PROPERTIES
  • Stiffness
    Stiff
  • Structure
    Closed
  • Surface/Texture
    Matte, Texture
  • Transparency
    Opaque
  • Surface Hardness
    Hard
CERTIFICATIONS
  • N/A
Sustainability
SUSTAINABILITY
  • Lightweight