The Cost of Prototyping CFRP and Carbon Vol.4 Companies that Handle CFRP Prototyping and Final Summary

Contents

Introduction
Overview
Companies that Handle CFRP Prototyping and Fabrication
- In the case of autoclave molding
Summary

Introduction

We hope that Vol.1 through Vol.3 has offered you a concrete image and insight into the costs involved in CFRP and carbon prototyping.

Overview

In the final volume for this series (Vol.4), we are going to look at what types of companies deal with CFRP fabrication.

Companies that Handle CFRP Prototyping and Fabrication

What type of company handles CFRP prototyping and fabrication? This may seem like a simple question, but varying factors including the size, form, and properties of the product, the quantity and cost of fabrication, and the availability of adequate facilities will dictate whether a company can handle the request.

In the case of autoclave molding

the internal dimensions of the autoclave will determine the maximum possible size for the product. When it comes to autoclave facilities, “the bigger the better.” And at Uchida, we house a Φ3m × L6m large-scale autoclave, enabling us to fabricate bulky and large-scale products.

In medium-mass production, companies are often divided by volume as well as specific fields according to their acquired certifications, specialties, and strengths. Fields vary from general consumer goods, sports, and leisure to specialized fields such as aerospace and defense, medical and welfare, and artistic works. In the case where the product specifies a particular material, the company’s carbon fiber supplier will also be a determining factor.

Autoclave

φ3m × 6m (depth), temperature MAX 200°C : pressure MAX 1.0MPa

φ1.15m × 1m (depth), temperature MAX 400℃ : pressure MAX 2.0MPa

Summary

This series detailed the costs involved in CFRP prototyping. Now let’s do a quick review of the key points to take away.

Point 1

Single-item production incurs initial costs in structural design, molds, manufacturing design, and production.

Point 2

Single-item production has an unfavorable material yield for prepregs and molds.

Point 3

Because of the degree of freedom afforded by anisotropic design, the costs cannot be expressed in terms of price per weight (e.g., $100/kg) as with metals.
General reference: The weight conversion of a typical prepreg material is approximately 1 2,000 JPY/kg (90 USD/kg*).

Point 4

The manufacturing process necessitates a range of facilities and equipment. Many of the processes are completed by hand due to the complexity of CFRP manufacturing, adding to the production costs.

When talking about costs, while the disadvantages tend to stand out, one should not focus solely on the cost of the product itself. Rather, we encourage you to carefully consider the use of carbon and CFRP products, taking into account the bigger picture such as the total cost, advantages such as fewer parts, energy savings, lower transportation costs, and space savings due to integrated construction and weight reduction, including peripheral equipment.

*Prices converted at a rate of 135 JPY to the USD, as of May 2023. Please note that prices are for reference use only and may vary.

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