The Cost of Prototyping CFRP and Carbon Vol.3 Facility Costs and Lead Times

Contents

Introduction
Overview
Facility Costs
Lead Times
Summary

Introduction

In Vol. 2, we delved into the material and labor costs of CFRP fabrication. Now that we have a clearer picture of the material costs and the worker (technician) involvement in CFRP manufacturing and prototyping, let’s probe a bit further.

Overview

In Vol.3, we will delve even deeper and discuss the facility costs and lead times associated with CFRP and carbon prototyping.

Facility Costs

First, we will look at the facilities and equipment for CFRP and carbon prototyping. While CFRP mold processing necessitates high-precision machining centers, as CFRP products or molds are incompatible with machining oils, a dry operation is required. As mentioned previously, prepregs are raw materials with a use-by-date that need to be freezer controlled. Typically manufacturer requirements specify that prepregs storage in temperatures below 18℃. Moreover, the laminating process requires a clean room with careful temperature and humidity controls to prevent contamination from foreign substances and maintain the material quality (*The degree of cleanliness required will vary by field, application, and customer needs). CFRP production also requires compressors for adjusting the pressures inside the autoclave chamber during molding, as well as specialized non-destructive and other testing devices for detecting foreign matter or voids between layers during final inspection. Such defects are not detectable from external observation.

Lead Times

A quick overview of production times for prototyping. Customer input and the complexity of the product will greatly influence production times in prototyping. In the case of flat lamination designed shapes with drawing plans, fabrication can be completed in one to two weeks. While more complex components will entail an initial structural planning phase of 2–3 months plus approximately 6 months for fabrication.

That said, in the motorsport world “time is of the essence” and car race dates cannot be changed. There are cases where we receive a consultation on the weekend and have the product out by Monday morning. In some way or other, we make it work. This kind of versatility is owed to the skilled workmanship and flexibility afforded by our technicians.

Summary

In this volume, we focused on the facility costs and lead times associated with CFRP and carbon prototyping. We hope this armed you with knowledge and insight into the specialized facilities and environments that underpin CFRP production. Lead times vary drastically depending on the job, but hopefully our examples give you a general outline of what to expect. So far, we’ve covered the well-equipped facilities, the environment, and the people involved in CFRP prototype manufacturing. In the final Vol.4 of this series, we will cover entities and companies that deal with CFRP manufacturing.

DMG MORI TVCM Front Runner Vol. 46 UCHIDA

ABOUT UCHIDA - 55 years since our founding

We leverage a wealth of technical expertise as a CFRP molding and processing manufacturer using FRP, GFRP, and CFRP materials. We offer a one-stop solution, encompassing design, analysis, manufacturing, secondary processing, assembly, painting, quality assurance, and testing.

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UCHIDA's equipment

We have cutting-edge equipment to ensure that we can address even the most advanced challenges of our customers.

DMG森精機 - VS1000/40/2050
X軸：2,050mm（ストローク）／ Y軸：1,000mm ／ Z軸：600mm ／テーブル作業面：2,250×1,000mm

ASHIDA MFG Co., Ltd.
Autoclave Oven 2
Size : Ø1,150x1,000mm / Operating temperature : at normal temperature - 400℃ / Design pressure : 2.0Mpa (maximum working pressure) / Vacuum system : back suction system / Vacuum units : 5

ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000x6,000mm / Operating temperature : at normal temperature - 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ - 0.99Mpa/cm²） / Boost pressure accuracy : 0 - 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10

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Oven
Size : W1,000xH1,000xD1,000mm / Temperature range : Environmental Temperature +20 - 300℃ / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 45min less / Vacuum system : back suction system / Vacuum units : 10

ESPEC CORP.
Temperature & Humidity Chamber

INSTRON
Static Universal Testing Machine 5985

Oven
Size : W7,000xH3,000xD2,000mm / Temperature range : Environmental Temperature +20 - 300℃ (Max) / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 60min less / Vacuum system : back suction system / Vacuum units : 10

NEO
X axis : 4,000mm (stroke) / Y axis : 2,000mm / Z axis : 1,200mm / C axis : 0° - ±270° / B axis : 0° - ±110° / Table working place : 4,000x2,000mm

【開発】
3Dプリンター | Markforged

Painting booth
Various painting, and clear finish is done in dedicated painting booth

Adhesion, Finishing, Coating Room
Finishing process, such as trimming, drilling, and bonding, surface treatment of the molded product type and is done in a private booth

Toshiba Matrixeye EX (Ultrasonic flaw detector)
Matrix-Arrey : 32

AMETEK CREAFORM Metra
SCAN750 Elite (3D scan)

Olympus Corp.
Inverted Microscopes

Oven
Size : W450xH450xD450mm / Temperature range : Environmental Temperature +20 - 650℃ / Temperature elevation capability : Environmental Temperature+50 - 650℃/120min less

Cutting Plotter Table working place : W1,500xL3,500mm

SHIMA SEIKI MFG., LTD
Cutting Plotter

KUKA
Robot

Krauss Maffei
Epoxy resin injection machine Resin 60L ／ Hardener 25L

Krauss Maffei
630t Press machine Height total 5,200mm ／ Length max 1,500mm ／ Width max 1,200mm ／ Whole cycle time per component part 240sec

DMG森精機 - NV5000B/40
X軸：1,020mm（ストローク）／ Y軸：510mm ／ Z軸：510mm ／テーブル作業面：1,320×600mm

Big sized clean room
JIS B 9920 cleanliness class maximum concentration (Pcs/m³） / Class 5 : 100,000m³ / Capacity : m² (16,000x16,000mm) 760m² (16,000x16,000x3,000mm) / Temperature and humidity condition : Temperature : 23℃±3℃, Humidity 65% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Temperature -5℃ during winter, Humidity 40% less