The Cost of Prototyping CFRP and Carbon Vol.2Material and Labor Costs

Contents

Introduction
Overview
Material Costs
- Molding Material Costs
- Product Materials
Labor Costs
- Technicians (personnel)
Summary

Introduction

In Vol.1, we covered the autoclave molding method, hopefully providing you with deeper insight into the processes involved in manufacturing CFRP.

Overview

In this second part of series (Vol.2), we will delve into the material and labor costs.

Material Costs

Molding Material Costs

First, let’s take a look at gypsum (plaster). In Japan, prototype molds for CFRP are typically constructed with gypsum board. This material is similar to plasterboard used in housing and construction. Although gypsum board dimensions vary by manufacturer and lineup, most are approximately 1000 mm (W) × 1500 mm (L) × 50 mm (H). The board material is glued and thickened to match the size of the product and split structure of the mold, and then machined using our machining center. The cost is approximately ,000–60,000 JPY (300–445 USD*) per board based on fixed dimensions.

Product Materials

Now, let’s delve in to the prepregs. As mentioned previously, prepregs are broadly divided into two materials: carbon fibers and resins. Carbon fibers have a wide lineup with varying options in elasticity modulus (low, medium, high, and ultra-high) as well as diverse specific strengths ranging up to ultra-strong. In terms of form, the carbon fibers are either unidirectional (UD), whereby carbon fibers are aligned in one direction, or a woven fabric type design. At Uchida, we employ a combination of these forms accordant with the structure, design, and form of the product.

For resins, while epoxy resin is the common choice for prototype structural parts, other products with specific property or strength requirements may call for bismaleimide, cyanate, or polyamide resins, or prepregs with a thermosetting resin matrix. Although cost and production lot vary greatly depending on the use environment and specific properties, epoxy resin prepregs generally cost between 4,000–8,000 JPY/m²(30–60 USD/m²*). Materials for aerospace applications can cost up to 100,000 JPY (740 USD*) per square meter. Prepregs are thin sheet materials with a thickness of about 0.08–0.7mm per layer which are laminated, using multiple layers, based on the design of product.

Labor Costs

Technicians (personnel)

Finally, we’d like to discuss the labor costs and processes. In Vol.1, we focused on CFRP fabrication using the autoclave molding method. However, many of the processes are performed by the hands of technicians and workers.

UCHIDA WORK FLOW

At Uchida, we handle many requests for complex or large structural forms and products, one-of-a-kind items, and prototype development. Prototypes demand short lead times and rarely have the capital or time for mechanization. Versatility and accommodation depend on the skill of our technicians, an area where we excel. Moreover, machining techniques for CFRP are still in their infancy and thus limited to large simple forms such as aircraft-related products and roducts that have an established stable production line and quality assurance.

Summary

In Vol 2, we delved into the material and labor costs of CFRP and carbon prototyping. Hopefully, it provided you with you a clearer idea of the material costs as well as the vast amount of hands-on work that goes into manufacturing CFRP. Next up in Vol. 3, we will look at facility costs and lead times.

*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.

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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