What is CFRP Molding? Feature and Methods of CFRP Molding

Contents

Introduction
Key Concepts in CFRP Molding Technologies
Features of CFRP-molded Structures
CFRP Molding Methods
Summary

Introduction

Carbon Fiber Reinforced Plastic (CFRP) molding technology integrates carbon fibers with a polymer resin to achieve an ultra-lightweight and remarkably strong composite material. Numerous molding methods and technologies are being leveraged in performance-critical industries—such as aerospace, automotives, and sporting equipment—to maximize the inherent characteristics and advantages of CFRP.

This column delves into the various molding technologies and key characteristics of CFRP.

Key Concepts in CFRP Molding Technologies

CFRP is a composite consisting of carbon fibers solidified within a polymer resin matrix, offering an exceptional weight-to-strength ratio and durability. During molding, controlled thermal and pressure conditions are applied to strategically configured carbon fiber and resin formulations to achieve desired geometries and mechanical properties. CFRP molding is therefore closely linked to rigorous material selection and application-specific engineering, with various molding methods employed depending on the intended function and performance demands of the final product.

Features of CFRP-molded Structures

– Lightweight: CFRP is significantly lighter than metal, while maintaining rivalled or superior strength, making it ideal for aircraft and automotive parts where every unit of weight reduction directly enhances overall performance.

– High Strength and Rigidity: CFRP possesses excellent tensile and mechanical strength, providing remarkable structural integrity.

– Corrosion Resistance: Unlike metals, CFRP can effectively withstand harsh environmental, ensuring long-term durability without corrosion-related damage.

– Heat Resistance: Thermal stability is where CFRP excels, making it highly-suited to high-temperature environments and application such as aircraft and automobile engine components.

CFRP Molding Methods

CFRP components are produced using specialized molding techniques tailored to component geometry, specifications, and application environmental conditions.

Prepreg Molding

A prepreg molding utilizes carbon fiber sheets pre-impregnated with resin. These prepregs are consolidated and cured under controlled heat and pressure to produce complex geometries and precision components typically required in aircraft and automotives.

– Features: High dimensional accuracy, precision, superior structural strength, and quality consistency.
– Applications: Aircraft, high-performance sporting equipment, and precision automotive components.

Hand Layup Molding

In hand layup molding, carbon fibers are layered by hand and saturated with polymer resin using specialized brushes and tools. This method enables highly-customized production and tailored adjustments, making it well-suited to relatively low-volume production and intricate product designs.

– Features: Ideal for low-cost, low-volume production, and complex shapes.
– Applications: Custom-designed components, prototypes, and low-cost parts

Autoclave Molding

Autoclave molding is a high-precision composite manufacturing process in which polymer resins are cured under tightly-controlled temperature and pressure conditions. In this method, the materials are thermo-pressurized in an autoclave (pressurized heat furnace), to produce precision products with high dimensional accuracy, uniformity and structural integrity (strength). In aircraft and aerospace industries, this method is typically employed for high-performance, precision-critical components.

-Features: High quality and dimensional precision, high structural, and mechanical strength.
– Applications: Aircraft structural components and aerospace precision components

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

Resin Transfer Molding (RTM Molding)

In RTM molding, carbon fiber preforms are positioned within a closed metal mold and impregnated with resin, resulting in shorter production lead times for high-volume applications while maintaining high dimensional accuracy.

– Features: Suitable for high-volume production and precision components. Offers uniformity and consistent quality.
– Applications: Automotive and industrial components and construction materials

Hybrid Molding

Hybrid molding integrates CFRP with complementary materials (metals or engineering resins), strategically leveraging the strengths and properties of each material to achieve optimized performance and product functionality.

– Features: Performance optimization through multi-material integration.
– Applications: Automotive and aircraft components.

Summary

CFRP molding technology is used to produce lightweight, high-strength composite components for diverse applications including aerospace, automotive, and sporting equipment. While numerous molding methods and technologies exist, selecting the appropriate method—based on product specifications and application environmental conditions—is critical to ensuring optimal structural performance and effective production. Continued developments in lightweight and high-performance CFRP materials and molding technologies are expected to further accelerate innovation across diverse industrial sectors.

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