Advanced composites are quickly becoming the answer to some of industries most difficult questions. Most specifically those questions that ask for something that’s stronger than steel yet lighter than aluminum. This means that projects that used to be impossible are now just the opposite and troublesome parts now have an answer.

Advanced composites, namely carbon fiber, are a very different style of manufacturing than most other processes out today; and that must be understood before one can truly appreciate their abilities. Unlike plastics or metals, composites are actually two or more separate entities coming together to form one part. In the case of carbon fiber, a fabric of the woven carbon fibers is run through what they call a prepare, which is a kind of epoxy that when heated becomes very hard. The fabric is then cooled until it’s ready for use, at which time it is cut precisely by a pattern cutter to the right pattern. The pieces are then hand laid in a mold in a specific pattern which will give the finished part areas that can flex or be incredibly rigid, either way staying very strong and lightweight. The part is then put through a number of different processes, depending on the demands of the finished part. It can be bladder molded, which is basically putting a high strength balloon in between two layers of fabric, heating them up and blowing up the balloon to create a hollow part. It can be compression molded by closing the material in between two parts of a mold and heating it up. This creates a solid part such as the external fixation rings below. The piece can be made with a vacuum bag where the part is laid up in its mold and covered with a sheet of plastic film. The air is then removed from the inside, sucking the plastic down on top of the part. The piece is then put into an autoclave or an oven to cure. This process allows the use of a second material such as a foam core. Another process utilized is called mandrill wrapping where the fabric is wound around a mandrill to create a part such as a cymbal stand rod.

The beauty about carbon fiber/composite parts is that they can be made to just about any project, yet they aren’t perfect for everything. The laborious process of creating a carbon fiber part means that extremely high quantities are not able to be produced. Also, because of labor and the high cost of the fabric, the piece part price can be higher than other manufacturing processes. What this really means is that carbon fiber parts won’t be cost effective in all situations. Yet, its strength and lightweight properties make it an ideal product for many applications such as aircraft, automotive, military, sporting goods, healthcare, and many others. Although the initial cost of each piece may run higher, it is able to save money in the fact that it doesn’t require secondary finishing. The parts can be made to come out of the mold with a high gloss finished appearance.