What is Compression Molding in Carbon Fiber Manufacturing

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What is Compression Molding in Carbon Fiber
Manufacturing

• NITPRO COMPOSITES

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Introduction

• In carbon fiber product manufacturing,
  compression molding is a versatile technology.
  The innovative process involves placing a
  pre-heated composite material into a mold cavity
  and applying pressure to compress and shape the
  material into the desired form, creating a wide
  range of carbon fiber products. This method is
  commonly used for the manufacturing of
  high-quality carbon fiber sheets, rods, tubes and
  parts. The carbon fiber parts are used in
  industries such as automotive, aerospace, and
  sporting goods for creating lightweight and
  strong carbon fiber components. The carbon fiber
  industry relies on the molding process for parts
  of accurate dimension, superior mechanical
  properties of carbon fiber and excellent surface
  finish. The labor-intensive technology takes
  pride in versatility and accuracy. To explore the
  prospects of the technology it is essential
  understand the compression molding process and
  its applications in the composite industry.

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What is Compression Molding?

• The details of the carbon fiber manufacturing
  process are in its name. A mold cavity is heated,
  raw carbon fiber materials are placed and then
  subjected to heat and pressure to create the
  desired shape. This process allows for the
  production of complex shapes with high
  strength-to-weight ratios.

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Divided into four basic steps-
1. Prepare a heated mold. Then a precisely
measured amount of raw carbon fiber material
(sheet or prepeg) called the charge, often
preheated is placed into the open cavity of the
mold. 2. This step involves closing the mold.
The raw material is forced to spread and fill the
mold cavity. A hydraulic press ensure that
the carbon fiber (prepreg, sheet or other form)
reaches all corners and crevices of the mold. 3.
The mold with the compressed material is
maintained under heat and pressure. The process
of thermosetting makes the material undergo
a chemical reaction, permanently hardening it
into the desired shape. The curing process
is based on the carbon fiber produced. A carbon
fiber sheet will have a differing curing time
than a rod or any other shape. 4. The
product has cured. After the pressure and heat
has been released, the mold opens. Now, the
finished part is ejected from the mold
cavity. In many cases, excess material (flash)
will be needed to be trimmed for a clean
finish. Now, most compression molding methods
follow the four steps. The manufacturing method
can be further classified into other
specialized methods.
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1. Cast Molding

• In this process, the composite material is placed
  into a mold and then compressed using a hydraulic
  press. The method is cost-effective and
  efficient, specially for large scale production.
  Cast molding for carbon fiber products is
  commonly used in the automotive and sports
  industries. The method is used for lightweight
  and high strength car body panels, sports helmets
  and tennis rackets.

2. Bladder Molding
The technique uses an inflatable bladder of
silicon or rubber placed into the mold before the
carbon fiber composite material. The mold is then
heated and the bladder is inflated pressing the
composite material against the heated mold giving
it the desired shape. Bladder molding is commonly
used in the aerospace industry to produce parts
such as wings and fuselage panels. It is also
used in the manufacturing of medical equipment
and orthopedic parts such as prosthetics and
braces.
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3. Transfer Molding
The technique uses a plunger to transfer the
composite material into a heated mold. The
composite material is forced it into the mold
cavity. The mold is then heated to cure the
composite material and give it its final
shape. Transfer molding is commonly used in the
electrical and electronic industries for
producing parts such as circuit boards and
electrical connectors. Besides the three common
methods, there are specialized techniques such as
injection molding. With the advancement in the
carbon fiber industry, new technologies and
methods are being explored to expand the
potential of the composite material to create
incredible high strength and low weight
products. Now, looking at the advantages and
disadvantages of compression molding a
manufacturer can decide whether to use the
technology for their carbon fiber production.
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Advantages of Compression Molding
Disadvantages of Compression Molding

1. A higher chance of post-molding costs.
2. Slower processing times.
3. Not suitable for all complex designs.

1. A relatively simple and straightforward compared
   to other molding and manufacturing processes. For
   some part designs this makes it easier for
   operators to perform, which translates to lower
   overall production costs.
2. Lower tooling costs is an added bonus, as it does
   not require special equipment and expensive
   complex tooling. It typically means less capital
   investment. Although it is a labor-intensive
   process it can still be cost-effective.
3. Great for producing large items and thicker parts.

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Applications of Compression Molding Process
The compression molding process finds numerous
applications in the carbon fiber composite
industry. Some of them include
Aerospace Industry The process is used to
produce a wide range of aircraft components,
including structural parts, landing gear, and
engine components.
Automotive Industry Car body panels and even
engine parts for lightweight, high-performance
parts results in fuel efficiency, improved
performance, and reduced emissions.
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Sports Equipment, including bicycle frames, golf
club shafts, and tennis rackets.
Compression molding is a versatile and effective
technique for manufacturing high-performance
carbon fiber products. NitPro Composites prides
in being a reputed manufacturer in the carbon
fiber industry. Offering high-quality carbon
fiber products as well as catering to customized
requirements in the automotive, sports, medical,
or aerospace industries, explore our
manufacturing capabilities.
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Thank You
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