What are composites and carbon fiber?
Fibrous Composites
Composite materials are created by combining two or more different materials in order to create a new material that has better properties than the combined materials individually.
Fibrous composites have deeply penetrated the industry as they can replace metals or other materials while retaining mechanical properties while reducing the weight of a structure.
A composite material consists of the matrix and the reinforcement means.
Carbon Fiber
The fibers are made of carbon atoms whose bonds are approximately parallel to the fiber axis.
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Carbon Fiber Properties
in relation to direct substitutes
| Density | Modulus (Gpa) | Tensile Strength (MPa) | Specific stiffness (GPa) | Specific Strength (MPa) | |
| Carbon | 1.8 | 230 to 820 | 2000 to 7000 | 128 to 455 | 1111 to 3900 |
| E-Glass | 2.5 | 70 | 1700 | 28 | 680 |
| Aramid | 1.4 | 130 | 3000 | 98 | 2140 |
| Polyethylene | 0.97 | 170 | 3000 | 175 | 3090 |
| HT Steel | 7.8 | 210 | 750 | 27 | 96 |
| Aluminium | 2.7 | 75 | 260 | 28 | 96 |
Construction Methods
How We Work
Design
The basic concern is the client’s needs and requirements to achieve the best result.
Mold manufacturing
The construction of the mold that will give the final shape to the project begins.
Product and material build
Depending on the geometry and properties of the product, the manufacturing method is chosen.
Delivery
Completion, check, shipping
Design
The basic concern is the client’s needs and requirements to achieve the best result.
Mold manufacturing
The construction of the mold begins and will give the final shape to the project.
Product and material build
Depending on the geometry and properties of the product, the manufacturing method is chosen.
Delivery
Completion, check, shipping
Areas of occupation
Manufacture of Composite Materials Products
Construction Methods:
Wet Lay-Up
The fabric is placed in a mold and then scattered inside the resin to the point of maximum filling (saturation point).
The process is repeated in more than one layer of fabric, depending on the required mechanical properties.
The manufacture is left under ambient conditions until the resin hardening process is complete.
It is noted that prior to the 1st layer of fabric, the mold may be coated with a non-reinforced polymer sheet (gel coat) which will form the outer surface of the fabric.
Wet Lay-Up Vacuum Bagging
The fabrics are resin-impregnated and impregnated, as in the Wet Lay-up method, and then applied to the vacuum fabrication process for better homogenization of the material.
The vacuum is achieved by sealing the construction using a special bag and vacuum pump air removal.
Vacuum infusion
Vacuum infusion is a process of manufacturing composite materials using a closed mold.
The vacuum system absorbs the resin until the reinforcement medium is fully saturated.
It is noted that this method is completely controlled, as it is governed by Darcy's law. Factors affecting it are (a) the reinforcement medium, (b) the polymer viscosity, and (c) the differential pressure between the atmosphere and the system.
As long as these three parameters remain constant during the process, this method ensures the desired result.
Finally, it should be noted that the vacuum resin injection is environmentally friendly, as the system does not come into contact with the atmosphere (closed mold process).
Light RTM
Two molds are used in the LRTM (Light Resin Transfer Molding) method. One is the base and is coated with the fabrics and the second is flexible and seals with the base, creating a closed two-mold system. Then, with or without the aid of a pump for resin transfer, saturation of the reinforcement is achieved.
This procedure ensures:
• High productivity
• Reduced labor costs
• Good surface on both sides
• High geometric integrity
• Absolute control of the process
• Stable mechanical properties
• Long mold life
• Environmental friendliness
Autoclave Prepreg
This method uses fabrics containing a certain percentage of resin (prepreg fabrics / prepreg).
Once coated in the mold with the appropriate technique, they are sealed and then inserted into the autoclave.
By applying pressure in the oven cabin, system pressure (double molding), and high temperature, complete polymerization of the material is controlled by achieving upgraded mechanical properties.
Out of Autoclave Prepreg (OOA)
This method is similar to the Autoclave method except that no positive pressure is used in the oven cabin.
In recent years, polymer systems have been developed which, with appropriate techniques, can impart mechanical properties to the material that are comparable to those developed through the autoclave method.
This enables us to manufacture high-quality mechanical products without the use of expensive machinery, offering flexibility in the manufacturing process.
Moldless Constructions
This method uses a pre-processed foam piece (epoxy, polyurethane, XPS, PVC etc.) to coat the reinforcing material giving it the final shape.
This method is often used for the production of prototypes or models.
Often the foam enclosed in the material remains, imparting toughness and rigidity to the fabric.