How to design a carbon fiber parts?

How to Design a Carbon Fiber Component: A Guide for Modern Technology Applications

In industries such as automotive, aerospace, sports, and space technology, where maximum performance, minimal weight, and extreme durability are critical, designing high-quality carbon fiber components requires a complex process that begins with a concept and ends with the final product.

This article outlines the key stages of designing a carbon fiber component, from idea generation and digital design to the finished product.

1. Material Selection and Foundation Preparation

Designing a carbon fiber component begins with defining the purpose and function of the part. Carbon fiber, known for its exceptional strength-to-weight ratio, is the cornerstone of this process. The selection of the right type of carbon fiber and resin, as well as an understanding of the operational requirements of the component, lays the groundwork for success.

2. Digital Design – Advanced CAD and Simulation Tools

From surface design of the part, the process transitions to selecting appropriate materials and technologies, followed by the phase of designing the composite fiber orientation. With modern digital tools, designers can precisely design and simulate every detail of the part, accounting not only for dimensions but also for the forces and their directions acting on components under real-world operating conditions.

Software like Fibersim NX by Siemens enables the creation of accurate 3D models and load simulations, ensuring that the part will possess the required mechanical properties.

Initially, a prototype model is created, typically using 3D printing, serving as a form that allows verification of the shape’s correctness and assembly constraints at a 1:1 scale.

After this phase, the designer also determines the fiber layout within the carbon fabric, which can significantly influence the component’s strength in various directions. Once the design is complete, a digital analysis is performed to assess how the part will behave in reality under static and dynamic external forces (e.g., tensile, compressive, or impact forces).

3. Tool Preparation

There are several methods for tool preparation, such as metal molds or those made from epoxy blocks through 3D printing. However, the highest quality results are achieved using composite molds made of carbon fiber. This is due to their high shape stability across a wide temperature range and the relatively thin surface layers of the molds, which is advantageous in the forming process of prepregs, whether in a heating chamber or an autoclave.

In general, tool preparation can be carried out in various ways depending on the chosen technology. For prototype production, methods such as 3D printing or CNC machining are often used, as they allow for quick and precise fabrication of preliminary components.

Once the mold is ready, it undergoes the curing stage (thermal processing), during which the material acquires its final mechanical properties.

4. Molding

Regardless of the type of mold used, once the digital design is approved, the part formation process begins. Prepreg fabrics—whether carbon, aramid, or hybrid—are pre-cut using a cutting plotter and prepared in the required layers. These layers are then arranged within the molds in the designed configuration to achieve the optimal properties of the part.

Typically, the fibers are laid in various orientations to ensure high tensile and compressive strength or to enable flexible load absorption, depending on the part’s intended application.

5. Curing and Finishing – Production Finalization

After laying the carbon fiber layers into the appropriate mold, the product is placed in a vacuum bag and transferred to an autoclave—a specialized chamber where the material is cured under high pressure and temperature while simultaneously removing air from the vacuum bag. This process, known as polymerization, occurs at temperatures ranging from 120°C to 180°C, depending on the type of resin used in the prepregs. The autoclave provides optimal conditions for composite lamination, ensuring maximum strength and material stability.

Once cured, the parts undergo further finishing operations such as sanding, drilling, or cutting. These tasks are performed with precision CNC tools to achieve the perfect shape and dimensions of the component. However, for delicate parts, manual work by an operator often remains the most practical solution.

6. Quality Control – Reliability and Precision

Every finished component must undergo rigorous quality control. Engineers assess the material’s strength, dimensional accuracy, and product aesthetics. Advanced testing technologies, such as ultrasound inspections and strength tests, ensure that the component meets the highest quality standards.

Carbon composites are often subjected to real-world condition testing, such as durability trials, to confirm their performance in the intended environment, regardless of variables like temperature, humidity, or other factors.

6. Applications and the Future of Carbon Fiber Technology

After the production process is complete, the finished component is integrated into its final application—ranging from supercars and airplanes to sports equipment. Thanks to the material’s unique properties, such as lightness, strength, and corrosion resistance, carbon parts are revolutionizing the automotive, aerospace, and sports industries. They contribute to vehicle weight reduction, system efficiency, and enhanced performance.

The future of carbon technology also lies in the development of more sustainable production methods. As technologies evolve, it becomes possible to lower production costs, improve energy efficiency, and enhance the recyclability of carbon fiber, making it increasingly accessible and environmentally friendly.

Summary

Designing carbon fiber components is a complex process that requires advanced technology, precise design, and quality control at every stage. While production costs can be high, the advantages of such materials—lightweight, durability, and corrosion resistance—make them highly versatile across numerous industries.

Carbon fiber technology not only enhances machine efficiency but also transforms how we design the future of transportation, sports, aerospace, robotics, and medicine.