FRP and CFRP Type Molds

Introduction

The term carbon fiber has become high-use jargon in recent years. While most people know it is a lightweight and strong substitute material for metal, frequently used in commercial planes and automobiles, that’s usually the extent of information we have. So, what else is there to know about this material?

Overview

Modern carbon fiber technology (material) originated in Japan and is now widely employed combination with a polymer plastic matrix to create composite materials known as carbon fiber reinforced plastics (composite material). In this section, we’ll discuss the molding dies used when forming/molding CFRP.

CFRP Characteristics

CFRP is distinguished by “lightweight, strong, and non-corrosive” characteristics. Read more here in our previous articles.

A Lighter and More Durable Material—CFRP

CFRP’s Potential

CFRP Manufacturing Methods

Although CFRP has various advantages, what manufacturing methods are utilized?

In this section, we will focus on two key topics: 1) Autoclave Molding as the leading molding technique, and 2) Prepregs, the core CFRP material used in Autoclave Molding.

Carbon & CFRP Autoclave Molding?

Prepregs: What are CFRP Prepregs?

CFRP Molding Dies (Molds)

Thus far, we have explored the key characteristics of CFRP. But what about the molds required for CFRP production? In this article, we will look at the mold materials and their varying uses.

Prototype Molds (Gypsum)

Gypsum, or plasterboard, is widely used in Japan for prototype development and small-lot production (1-10 products).
First, we bond the gypsum-based board material to the through-thickness direction (Z-direction, perpendicular to the surface) of the product, to create width and then we fabricate and shape the mold in our machining center.

*This is called a straight carving mold.

After processing, we seal and finish the surface with resin and then release the mold to complete production.

Advantages

• Low coefficient of linear expansion and good compatibility with CFRP
• High machinability
• Fast turnaround (short lead time)
• Lighter and easier to handle than metal molds.

Disadvantages

• Brittle and susceptible to chipping.
• Low durability
• As an insulating material, it generally has poor heat dissipation and long mold formation times.

FRP Inverted Molding (Hand Lay-up Processing Method: GFRPs and CFRPs)

A method often used for small production lots of 30–100 products. We machine an exact duplicate of the product (called a prototype or master profile) and then use this to produce an inverted mold.

Advantages

• Low coefficient of linear expansion and good compatibility with CFRP
• High machinability
• Fast turnaround (short lead time)
• Lighter and easier to handle than metal molds.

Disadvantages

• Brittle and susceptible to chipping.
• Low durability
• As an insulating material, it generally has poor heat dissipation and long mold formation times.

FRP Inverted Molding (Hand Lay-up Processing Method: GFRPs and CFRPs)

A method often used for small production lots of 30–100 products. We machine an exact duplicate of the product (called a prototype or master profile) and then use this to produce an inverted mold.

Advantages

• Lightweight and easy to handle
• Highly durable
• Short molding times (molding according to the product material) made possible with good heat dissipation
• Hand lay-up fabrication method of master profile eliminates the need for heat-resistant materials.
• The split position (division position of the mold) can be set arbitrarily, even for complex shapes.

Disadvantages

• Comparatively high expansion–contraction during molding due to the large volume of resin used.
• Difficult to accommodate to minor profile modifications and design changes.

Summary

This article focuses on molds produced from carbon fiber reinforced plastic (CFRP). Despite being a cutting-edge material, there is still limited understanding due to a lack of available information. The production lot volume, size of the product, and required versatility for design modifications governs which molding method we employ. Selecting the optimal method for the job is crucial and, depending on the industry or enterprise, we may even use metals to create a metal die. Ultimately, the most important factor is “what” and” how many”. Mold creation hinges on a detailed understanding of the product design aims and specifications and, thereby, must be conducted with a clear vision of the product’s key features and strengths.

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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

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

Krauss Maffei
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DMG森精機 - NV5000B/40
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