How to Choose a CFRP Mold Manufacturer

Contents

Introduction
- From a Molding Manufacturer’s Perspective
Towards Actual Production
Selecting a Mold Manufacturer
- Each molding manufacturer has different strengths and features.
What We Can Do at Uchida
Uchida Facilities and Equipment
- CFRP Molding Methods

Introduction

From a Molding Manufacturer’s Perspective

The “lightweight, strong, and non-corrosive” advantages of CFRP and composite materials have advanced product developments and applications across countless industries and markets. In this article, we’ll discuss what to look for when choosing a combined molding and composite product manufacturer.

Towards Actual Production

Uchida wields 55 years of achievements in manufacturing carbon fiber reinforced plastic and composite material products. Commonly referred to as carbon or dry carbon, carbon fiber reinforced plastic (CFRP) will vary in terms of compatibility with the application environment or facilities depending on the profile of the manufactured product, the production volume, and production lead times.

At Uchida, we house a huge range of equipment including large-scale autoclaves, RTM, Va-RTM, press machines, and FDM 3D printers designed to mold carbon fiber. This means that we have what it takes to provide solutions and manufacture products that align with customers’ needs for product profiles, costs, and production volume.

UCHIDA Co., Ltd.-2

Selecting a Mold Manufacturer

So, what should you look for when considering conversion to CFRP and selecting a molding manufacturer?

Each molding manufacturer has different strengths and features.

A search through manufacturer websites will quickly reveal the different business areas where the company excels. Some will specialize in prototype development, while others focus on mass production, and so on. Not surprisingly, there are areas that each company can or cannot do. Here are a few examples:

・Unable to mold large items due to size limitations of the molding equipment.

・Performs molding but not secondary processing or assembly.

・Can perform all aspects of molding but doesn’t have ISO certification.

・Provides manufacturing but not product design.

・Cannot manufacture products without drawings.

・Unable to perform high-temperature manufacturing due to equipment limitations.

・Offer proposals based on only one fabrication method.

・Unable to perform final coating or painting.

And so on.

During the development phase, it is difficult for an untrained professional (general consumer) to determine the appropriate manufacturing method for the product.

What We Can Do at Uchida

Deliver One-stop Manufacturing

We deliver all aspects of CFRP and composite manufacturing from design analysis to CFRP fabrication, secondary processing, assembly, painting/coating, quality assurance, and testing all in one-stop.

Create Products for Diverse Industries and Needs

With origins in mannequin manufacturing, at Uchida, we have contributed to developments and successes in diverse fields including 2-wheel (race bikes) and 4-wheel (race cars, next-generation vehicles, optional parts) automobiles, aviation, aerospace, marine, robotics, defense, medical, welfare, sports, arts, and industrial machinery.

Versatility to Accommodate

Our full range of equipment, manufacturing environments, and long-accumulated technical know-how offer us the versatility to accommodate all kinds of CFRP prototype developments.

Uchida Facilities and Equipment

CFRP Molding Methods

Molding methods for CFRP are numerous and are selected according to the desired application, shape, and production lot.

Autoclave Molding

RTM (Resin Transfer Molding)　

Va-RTM (Vacuum Assisted Resin Transfer Molding)

Press Molding

Hand Lay-up Molding

Filament Winding Molding

Sheet Winding Molding

Pultrusion

3D Printer

At Uchida, we use the fabrication methods shown in red.

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.

See Details

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