CFRP: Exploring SMC and C-SMC Manufacturing

Contents

Introduction
Overview
A Look at SMC and C-SMC？
- Key Characteristics of SMC
Manufacturing Method
Summary

Introduction

These days, technical jargon such as FRP, CFRP, composites, and weight-efficiency often appear in the media for a range of applications. Such terms may be annexed with “lightweight, strong, and non-corrosive” materials that substitute metals. But what exactly are these materials?

Overview

Carbon Fiber Reinforced Plastics (CFRP), as the name implies, refers to plastics reinforced with carbon fibers. The initial letter refers to the type of fiber used; C being carbon, G being glass fibers, and A being aramid fibers. Since CFRPs are composed from a combination of reinforcing fibers and resin (plastic), they are referred to as a “composite” or “composite material”. In this section, we will introduce the characteristics and applications of CFRP.

A Look at SMC and C-SMC？

SMC stands for Sheet Molding Compound, a thermo-compression molding method whereby a sheet-like material is input into a metal die, which is heated, and then compressed using a press machine. SMC materials are an intermediate substrate made from glass or carbon fibers which are cut into predetermined lengths (approximately one inch long) and then impregnated with a mixture of resin, hardening agents, and mold-releasing agents. Carbon fiber-reinforced SMCs are referred to as C-SMC, with C being an acronym for Carbon.

Key Characteristics of SMC

(1) Short molding cycle

(2) The short fiber lengths of the SMC substrate material allow for high fluidity and simultaneous molding of ribs and inserts.

(3) As SMC doesn’t utilize continuous fibers, like in conventional CFRP, it can be designed to exhibit homogeneous isotropic properties similar to those of metals.

(4) However, because fibers are cut into short strands, SMC substrates cannot deliver the same level of performance exhibited by continuous fibers. In other words, we cannot maximize the characteristic strength of carbon fibers.

(5) The above characteristics have led to SMC materials being used as a replacement for aluminum and similar metals. Its application and uses continue to expand.

Manufacturing Method

CFRP offers diverse features and can be produced using various molding methods depending on the shape of the product, production lot, and structure or specifications. At Uchida, we can provide one-stop support for a wide range of molding methods starting from prototyping.

Summary

SMC and C-SMC materials are an intermediate substrate used for mass production of CFRP. As an advanced material, information on CFPR is still limited, making it hard to fully comprehend the bigger picture. The distinctive features of fiber reinforced plastic (FRP) are its “lightweight, strong, and non-corrosive” qualities. While CFRP offers impressive potential, it also has disadvantages such as manufacturing complexity and challenges regarding costs, mass production, and recyclability. We strongly urge you to consider adopting CFRP and GFRP for your next project with a thorough understanding of its strengths and disadvantages alike.

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