Features and Applications of CFRP Molds: Lightweight and High-Strength Composite Materials

Contents

Introduction
Basic Structure of CFRP Mold
Features of CFRP molds
CFRP Mold Manufacturing Methods
CFRP Mold Applications
Conclusion

Introduction

CFRP (Carbon Fiber Reinforced Plastic) is a composite material with lightweight and high-strength properties that is widely used mainly in the aerospace, automotive, and sporting goods industries. CFRP molds are particularly powerful in situations where precision machining is required to reduce weight and increase strength. In this column, characteristics, manufacturing methods, and main applications of CFRP molds are explained in detail.

Basic Structure of CFRP Mold

CFRP mold is a composite material consisting of a resin (such as epoxy resin) with carbon fiber as a base material. CFRP type has different manufacturing methods and performance depending on its shape and design, but its basic feature is that it can achieve both weight reduction and strength improvement.

Features of CFRP molds

High strength and high rigidity

CFRP molds have high tensile strength and rigidity due to the properties of carbon fiber. This makes it possible to reduce the weight of parts that require strength, and improves resistance to mechanical impacts and loads.

lightweight

The greatest advantage of CFRP molds is their light weight. Although carbon fiber is much lighter than steel or aluminum, it exhibits equal strength, making it particularly suitable for applications requiring lightweight components, such as aircraft and automotive parts.

corrosion resistance

CFRP molds are more resistant to corrosion than metals. This allows it to maintain its performance for a long period of time even in harsh environments, and is especially used for parts that are susceptible to chemicals and moisture.

High degree of design freedom

CFRP molds are extremely free in molding and can reproduce complex shapes and fine details. The high degree of freedom in mold design allows for more freedom in the design stage, enabling the creation of products exactly as intended by the designer.

CFRP Mold Manufacturing Methods

There are multiple processes for manufacturing CFRP molds. The main manufacturing methods used are as follows

autoclave molding

Autoclave molding is a method of molding CFRP molds using pressure and heat. Autoclaves can produce very high quality CFRP products because temperature and pressure can be tightly controlled. This method is widely used in the aerospace and automotive industries.

– Features: high precision, high strength, and uniform molding

– Applications: aircraft parts, automotive parts

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

RTM (Resin Transfer Molding) molding

RTM molding is a molding method in which carbon fiber fibers are placed in a mold and resin is injected into them. The molding process is called autoclave molding. This process can be produced at a lower cost than autoclave molding, but may be slightly less precise and stronger.

– Features: low cost, relatively quick production

– Applications: sporting goods, building materials

Hand Stack Molding

Hand stack molding is a method where carbon fiber is stacked by hand and infiltrated with resin. This method is suitable for small-lot production and prototypes, but not for mass production.

– Characteristics: Allows fine adjustments by hand, for small lots

– Applications: Prototypes, custom products

Prepreg Molding

Prepreg molding is a method of molding using prepreg in which resin has been pre-impregnated into the fibers. This allows for the efficient production of high-precision products.

– Features: high precision, rapid production

– Applications: aircraft parts, sporting goods

CFRP Mold Applications

CFRP molds are ideal for products that require light weight and strength. They are utilized in the following fields.

Aerospace Industry

CFRP molds are used for structural parts of aircraft, wings, and parts of airframes. CFRP molds are lightweight and high-strength, contributing to improved aircraft performance.

automotive industry

CFRP molds are used in automobile body panels and chassis parts, and even in racing car parts. The weight reduction improves fuel efficiency and speed performance.

sporting goods

CFRP molds are also used in sporting goods such as bicycle frames, golf clubs, and ski boards. Because of its light weight and high strength, CFRP mold can maximize athletic performance in sporting goods.

building materials

CFRP-type is also used as a reinforcing material in buildings, especially for reinforcement to improve earthquake resistance.

Conclusion

CFRP molds are composite materials that simultaneously reduce weight and increase strength, and are used in a variety of fields, including aerospace, automotive, and sporting goods. In terms of manufacturing methods, technologies that combine precision and efficiency are evolving, and it is expected that CFRP molds will be used in many more industries in the future. the selection of materials at the design stage is a very important factor, as the performance of a product can be significantly improved by choosing CFRP molds.

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

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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