How We Manufacture Monolithic Carbon Fibre Sheets and Plates

Carbon fibre products can be manufactured via a number of different methods such as in an autoclave (prepreg), press, via liquid moulding, hand and wet lay-up. Each method has its advantages and disadvantages in terms of production output, cost and quality of the resulting final carbon fibre products. You should therefore be mindful when deciding which carbon fibre product on the market is right for your application; how is the carbon fibre sheet in question made. The type of resin used in the manufacture of the carbon fibre sheet will also effect the performance and the machinabilty of the carbon fibre sheet. Thermosetting polymers such as polyester, vinylester and epoxy are common resins, with epoxy resin possessing the best performance characteristics such as strength, stiffness and dimensional stability as well as great aesthetics.

 

Here at Juno Composites we use a liquid moulding method to produce our carbon fibre sheets.

How we make our carbon fibre sheets

  1. A carbon fibre preform is designed to ensure maximum performance and dimensional stability is achieved as a balanced (see tech section) symmetrical material structure is attained ensuring the final carbon fibre sheet will stay true and not warp.
  2. The dry carbon fibre perform is placed in the mould in the required orientations,

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  3. The mould is then closed and pressure applied to the carbon fibre perform to consolidate it increasing the fibre volume fraction (Vf %)
  4. the mould is then heated and an ultra low viscosity epoxy resin is injected through one or more inlets strategically positioned in the mould, soaking/impregnating the carbon fibre perform and filling the mould cavity evacuating entrapped air.
  5. When the mould is filled, the resin supply is removed, mould inlet and outlets are sealed and heat is then applied and epoxy resin is then allowed to completely cure; changing from a sol (liquid) into a gel and into its final glass phase.
  6. After cure has completed the part is then extracted from the mould.
  7. A protective plastic film is then applied over the gloss finish of the carbon fibre part and finishing operations such as trimming and sizing are preformed.