Carbon fiber manufacturing is the process of creating carbon fiber reinforced plastic (CFRP) with high strength-to-weight ratios and superior thermal and conductive properties. The process involves transforming raw materials into thin carbon filaments through wet spinning. Each manufacturer uses a unique blend of materials and temperature ranges, resulting in subtle differences in carbon fiber materials. Carbon fiber is used in aerospace, marine, sporting goods, and wind energy industries.
Carbon fiber manufacturing is the process of creating carbon fiber reinforced plastic (CFRP). Products made from carbon fiber offer one of the highest strength-to-weight ratios of any material and also offer superior thermal and conductive properties. This high strength and low weight makes carbon fiber manufacturing a popular choice in the aerospace, marine and sporting goods industries. Some carbon fiber material blends may also be called graphite.
The carbon fiber manufacturing process begins when manufacturers transform raw materials into thin carbon filaments. They start with a base of coal tar, or pitch, which is used to make low-end carbon fiber products. For high-quality products, manufacturers start with a base material of polyacrylonitrile, which consists of propylene and ammonia. After this base material has been heated several times, it changes the structures drastically. Eventually, the material turns into a chain of carbon molecules and all other molecules fall out.
These carbon molecules are mixed with chemicals and subjected to a process known as wet spinning. During wet spinning, the liquid carbon mixture passes through a die known as a spinneret, which has many small holes. The spinneret forms the material into long, thin filaments of carbon. By mixing these filaments with epoxies or other resins, manufacturers can produce CFRP.
The production of carbon fiber is quite precise and even a small change during production can have an impact on the quality of the product. Each carbon fiber manufacturing facility uses its own unique blend of base materials, chemicals, and temperature ranges during this manufacturing process. This leads to subtle differences in carbon fiber materials from one manufacturer to another.
Manufacturers shape carbon fiber into a variety of products using different types of manufacturing processes. They can create fiberglass or metal molds to cast individual parts. Fused carbon fiber reinforced plastics are often layered with mesh sheets for added strength and stability during the molding process. Companies can also extrude fused carbon fiber plastic through a steel mold to form different shapes.
Since its invention in the mid-20th century, carbon fiber manufacturing has been used to produce aircraft, boats, and automobiles. Since that time, it has also been used extensively to produce sporting goods such as bicycles, tennis rackets, and gold clubs. By the early 20th century, the wind energy industry had become the world’s largest consumer of carbon fiber, which is used to make large-scale wind turbines.
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