Our Manufacturing Facilities

Here at Carbonage Composite manufacturing plants, we develop our product using the following technologies: From the elementary fiber, a bidirectional woven sheet can be created, i.e. a twill with a 2/2 weave. The process by which most carbon-fiber-reinforced polymer is made varies, depending on the piece being created, the finish (outside gloss) required, and how many of this particular piece are going to be produced. In addition, the choice of matrix can have a profound effect on the properties of the finished composite. Many carbon-fiber-reinforced polymer parts are created with a single layer of carbon fabric that is backed with fiberglass. A tool called a chopper gun is used to quickly create these composite parts. Once a thin shell is created out of carbon fiber, the chopper gun cuts rolls of fiberglass into short lengths and sprays resin at the same time, so that the fiberglass and resin are mixed on the spot. The resin is either external mix, wherein the hardener and resin are sprayed separately, or internal mixed, which requires cleaning after every use. Manufacturing methods may include the following:



A) Molding

One method of producing graphite-epoxy parts is by layering sheets of carbon fiber cloth into a mold in the shape of the final product. The alignment and weave of the cloth fibers is chosen to optimize the strength and stiffness properties of the resulting material. The mold isthen filled with epoxy and is heated or air-cured. The resulting part isvery corrosion-resistant, stiff, and strong for its weight. Parts used in less critical areas are manufactured by draping cloth over a mold,with epoxy either preimpregnated into the fibers(also known as pre-preg) or “painted” over it. High-performanceparts using single molds are often vacuum-bagged and/or autoclave-cured, because even small air bubbles in the material will reduce strength. An alternative to the autoclave method is to use internal pressure via inflatable air bladders or EPS foam inside the non-cured laid-up carbon fiber.
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B) Vacuum bagging

For simple pieces of which relatively low volume are needed, a vacuum bag can be used. A fiberglass, carbon fiber or aluminum mold is polished and waxed, and has a release agent applied before the fabric and resin are applied, and the vacuum is pulled and set aside to allow the piece to cure (harden). There are two ways to apply the resin to the fabric in a vacuum mold.

The first method is manual and called a wet layup, where the two-part resin is mixed and applied before being laid in the mold and placed in the bag. The other one is done by infusion, where the dry fabric and mold are placed inside the bag while the vacuum pulls the resin through a small tube into the bag, then through a tube with holes or something similar to evenly spread the resin throughout the fabric.

A third method of constructing composite materials is known as a dry layup. Here, the carbon fiber material is already impregnated with resin (pre-preg) and is applied to the mold in a similar fashion to adhesive film. The assembly is then placed in a vacuum to cure. The dry layup method has the least amount of resin waste and can achieve lighter constructions than wet layup. Also, because larger amounts of resin are more difficult to bleed out with wet layup methods, pre-preg parts generally have fewer pinholes. Pinhole elimination with minimal resin amounts generally require the use of autoclave pressures to purge the residual gases out.



C) Compression molding

A quicker method uses a compression mold. This is a two-piece (male and female) mold usually made out of fiberglass or aluminum that is bolted together with the fabric and resin between the two. The benefit is that, once it is bolted together, it is relatively clean and can be moved around or stored without a vacuum until after curing. However, the molds require a lot of material to hold together through many uses under that pressure.


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D) Filament winding

For difficult or convoluted shapes, a filament winder can be used to make CFRP parts by winding filaments around a mandrel or a core.


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The Concept of Carbon Fiber in our Day to Day Products

Here at Carbonage Composite, we focus on developing our products in the following areas. With the use of CFRP in these applications, we are able to achieve in an increasing number of high-end products that require stiffness and low weight, these include:

• Laptop cases by an increasing number of manufacturers.

• Audio components such as turntables, loudspeakers and Hi-Fi Rack systems. • Musical instruments, including violin bows, guitar pick-guards, drum shells, bagpipe chanters and entire musical instruments.

• Kite systems use carbon fiber reinforced rods to obtain shapes and performances previously not possible.

• High-performance radio-controlled vehicle and aircraft components such as helicopter rotor blades.

• Tripod legs, tent poles, fishing rods, billiards cues.

• Many other light and durable consumer items such as the handles of high-end knives.

• Poles for high reach, e.g. poles used by window cleaners and water fed poles.


What is Carbon Fibre ?

Carbon-fiber-reinforced polymers are composite materials. In this case the composite consists of two parts: a matrix and a reinforcement. In CFRP the reinforcement is carbon fiber, which provides the strength. The matrix is usually a polymer resin, such as epoxy, to bind the reinforcements together. Because CFRP consists of two distinct elements, the material properties depend on these two elements.

The reinforcement will give the CFRP its strength and rigidity; measured by stress and elastic modulus respectively. Unlike isotropic materials like steel and aluminum, CFRP has directional strength properties. The properties of CFRP depend on the layouts of the carbon fiber and the proportion of the carbon fibers relative to the polymer.

At Carbon Age Composite, we have different ways of manufacturing CFRP. This is to ensure our customer’s products are developed and produced to meet the highest quality.



Carbon Fibre Products:

(Body Kits , Mirror Cover , Room Mirror Cover , OEM/Vented Hood , Front Bumper canard , Spoiler/ Wing , Trunk,Rear Diffuser , Front Fender , Side Skirt , Outter Door Handle Cover , Front Grill , Wheel cap cover , Air Intakes , Front Bumper , Front Lip , etc . )




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