Speaking of high-tech materials, which are applied in the aerospace, automotive, and sports industries, we can mention CFK (Carbonfaserverstarker Kunststoff), an example of one of the most powerful and lightweight materials on the market, carbon fiber reinforced plastic (CFRP). The process of producing carbon fiber composites Herstellung von CFK is a blend of state-of-the-art technology and craftsmanship. Let’s explore how it’s done.

Step 1: The manufacturing of Carbon Fibers.

The production of CFK starts with the making of the carbon fibers. They are normally composed of a polymer known as Polyacrylnitril (PAN). The fibers are made very strong and lightweight through a process of heating the so-called carbonization, which is done without the presence of oxygen. What is produced is a thin fibre of carbon just a few micrometers in thickness and yet very strong.

Step 2: Weaving and Layering

When carbon fibers are made, they are then woven as sheets or in forms of fabrics. This step is critical as the orientation of the fiber will be used to define the strength and flexibility of the end product. The layers may be either a single direction, woven, or a multidirectional depending on the purpose. As an example, in car production, special directions of the layers are selected to reduce the stress effectively.

Impregnation with Resin is the third step.

Then comes the matrix the plastic which holds the whole together. A harzsystem (resin system), normally epoxy, is impregnated into the carbon fiber fabric. This is referred to as Prepreg-Herstellung wherein the fibers and the resin are subjected to controlled heat and pressure conditions. This will achieve uniform distribution and bonding which is critical in getting maximum strength.

Step 4: Molding and Curing

The prepreg layers during molding are inserted in a mold where they are shaped to achieve a final shape. Then it is put in an autoclave which is a high pressure oven to harden the resin. The hot temperature and pressure make sure that the resin bonds with the fibers completely to produce a dense composite material that is not heavy.

Step 5: Final and Quality Control.

The CFK-Bauteile (CFRP components) are subsequently cured, trimmed, polished and defects checked. High-tech testing procedures, e.g. ultrasound or x-ray inspection, ensure that the components are of high quality standards - at least high-quality aerospace or motorsport components.