What is Carbon Fiber Reinforced Plastic (CFRP)? The Appeal of Lightweight, High-Strength Composite Materials

Contents

Introduction
Basic Structure and Properties of CFRP
CFRP Manufacturing Processes
CFRP Applications
Summary

Introduction

Carbon fiber reinforced plastic (CFRP) is a high-performance composite material based on carbon fibers. Despite being lightweight, it possesses exceptional tensile strength. This versatile material is used in numerous industries, including the aerospace, automotive, and sport industries. CFRP’s excellent properties enable the development of innovative products that deliver dramatic performance improvements compared to traditional materials.
This column outlines the basic properties, manufacturing processes, and primary applications of CFRP.

Basic Structure and Properties of CFRP

CFRP is a composite material that combines carbon fiber and resin (usually epoxy resin). This material has extremely high tensile strength, while remaining lightweight and highly resistant to corrosion. Thus, by hardening with resin, a lightweight material with exceptional strength and outstanding durability can be made.

Lightweight

CFRP is lighter than metals with equivalent tensile strength, like steel or aluminum. This makes it ideal for applications where weight reduction is critical such as aircraft components, automobile parts, and sport equipment. Furthermore, because it is light and strong, the material can effectively reduce structural loads.

Superb Strength

The inherent properties of carbon fiber give CFRP amazing tensile strength and pressure resistance. This allows it to maintain its shape even in environments where high forces are applied, while being resistant to breakage and deformation. CFRP performs well in applications where structural stability is required.

Corrosion Resistance

CFRP is more resistant to corrosion than metals. This property makes it highly resistant to moisture and chemicals, allowing it to maintain its performance over extended periods even in harsh environmental conditions.

Design Versatility

CFRP can be molded into complex shapes, offering tremendous design freedom. This capability allows us to pursue optimal designs tailored to the shape and function of the product.

CFRP Manufacturing Processes

Several manufacturing processes exist for CFRPs, each selected based on the material and intended application. The most common manufacturing methods include:

ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000×6,000mm / 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

Autoclave Molding

Autoclave molding molds CFRPs by strictly controlling the pressure and temperature. This method is widely used in the aerospace industry and for high-performance automotive parts where strength and precision are necessary.
Features: High precision and superb strength
Applications: Aircraft and automotive components

Resin Transfer Molding (RTM)

In RTM molding, carbon fiber preforms are positioned within a closed metal mold and impregnated with resin. This process enables the production of high-quality CFRP products in a relatively short time frame.
Features: Efficient manufacturing and cost-effective
Applications: Automotive parts and sports equipment

Hand Lay-Up Molding

Hand Lay-up molding is a method that involves manually layering carbon fiber and saturated with resin. While this method is suitable for small-scale production and prototyping, it is not practical for mass production.
Features: Production flexibility, ideal for small-volume production
Applications: Prototypes and custom products

Prepreg Molding

Prepreg molding utilizes prepreg, where carbon fiber sheets are pre-impregnated with resin. The process efficiently and precisely creates the desired products.
Features: High precision, suitable for mass production
Applications: Aircraft and sports equipment

CFRP Applications

CFRP is used in a wide range of industries due to its unique properties. Here are some examples of how it has been applied.

Aerospace Industry

CFRP’s lightweight and strong properties make it ideal for components used in aviation such as the wings, airframe, and engine. The material especially contributes to reducing the aircraft’s weight, which improves fuel efficiency and reduces operating costs.

Automotive Industry

Incorporating CFRP into an automobile’s body panels, chassis, and interior can reduce the vehicle’s weight and improve safety. In addition, CFRP plays an important role in maximizing performance in race cars and high-performance vehicles.

Sports Equipment

CFRP is extensively used in sports equipment, such as bicycle frames, golf clubs, and tennis rackets. Its lightweight yet high-strength properties can lead to improvements in the competitive field.

Construction

Since CFRP is corrosion resistance and earthquake resistance, the material is valuable in construction, especially when renovating or reinforcing a building. It has garnered particular attention as a seismic reinforcement material, playing an important role in earthquake preparedness.

Medical Field

CFRP’s combination of high tensile strength and light weight makes it suitable for medical devices such as prosthetic limbs and artificial joints. Additionally, it is also used in parts for radiation therapy equipment because it is radiolucent.

Summary

Carbon fiber reinforced plastics (CFRP) finds application across diverse number of sectors from aerospace and automobiles to sports equipment and construction, due to their light weight, high tensile strength, and corrosion resistance. Furthermore, as more efficient and precise manufacturing technologies are developed, CFRPs are expected to expand into more fields in the future. By using CFRP, manufacturers can improve product performance, reduce costs, and unlock new design possibilities, making it an important material that drives technological innovation.

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