Carbon fiber Molding parts

Carbon fibers are fibers made of carbon with the fibers being the base. Carbon fiber is materials consisting of thin filaments of carbon atoms by which when bound together with plastic polymer resin by heat or pressure, a vacuum of composite material is formed that is lightweight and at the same time durable. Carbon fiber is the combination of an estimated 50% carbon fibers, and 50% plastic, thus making it mainly a stronger plastic. Plastic by nature can break or crack easily, but when combined with the carbon fibers, its strength is increased.

The carbon fiber molding has its strength in the weave by which the more complex they are; the more durable the composite will be. This makes carbon fibers somewhat more expensive in weight when compared to fiberglass. Understanding the essential parts of carbon fiber, which are plastic and carbon fibers, one can agree that the essential concept of it is the compression. Products made with carbon fibers are compressed for the plastic to be evenly distributed throughout the fabric, leaving no room for cracks. Compression further makes it even in size and density.

Carbon fibers are by nature as rigid as steel and even as strong as steel. This makes carbon fibers chemically resistant and can tolerate high-temperatures with low thermal expansion. What makes the composite material unique is its vast importance in diverse fields like in aerospace, sports equipment, fishing rods, baseball bats, shoe soles, bicycle frames, case of laptops, even in some instruments of music, etc. It should not come as a shock that carbon fibers are also found in satellites, the oil and gas industry, furniture, bridges, wind turbine blades, etc.

However, the carbon fiber molding has its detractions as it is said to be costly in production. Carbon fiber molding parts, due to the cost of output, is not quickly produced in mass. The nature of the carbon fiber makes its production limited in some products, and this has caused the growth of synthetics that are similar to the carbon fiber. These copycats of the carbon fiber are simply plastics that imitates the carbon fiber molding, or just a few portions of carbon fiber is in them.

The use of liquids and gases and specific materials are essential in the manufacturing process of particular qualities, grades, and also effects of carbon fiber. Depending on the raw materials being used by manufacturers, there exists a difference in the combinations of raw materials being used and thus, they treat their formulas as trade secrets.

In the manufacturing stage of the carbon fiber molding, the precursors, which are the raw materials, are stretched into long fibers which are woven into fabrics or fused with other elements or molded into the shapes or sizes the manufacturer desires. In the manufacturing of carbon fibers through the polyacrylonitrile (PAN) process, there are five segments, which are:

a. The Spinning Phase: the polyacrylonitrile is mixed with other ingredients and then spun into fibers which are further washed and stretched.

b. The Stabilizing Phase: in this phase, there is chemical alteration used to stabilize bonding.

c. The Carbonizing Phase: after stabilizing bonds, the fibers are heated to the high temperature that forms tightly bonded carbon crystals.

d. Surface Treatment: the surface of the fibers are oxidized to improve the bonding properties.

e. Desired Sizing: the fibers are then coated and wound onto bobbins or cylindrical bars, which are further loaded onto spinning machinery that twists the fibers into different sizes. However, rather than being woven to fabrics, fibers are created into composites, which requires pressure, heat, or a vacuum that binds the fibers together with a plastic polymer.