How woven and forged carbon is made
Carbon fibers are nowadays an important material in many industries, from aviation to the car and motorsport industry. Two of the most popular forms of carbon are woven carbon and forged carbon. Although they both contain carbon fibers, the production methods and the end result differ considerably. In this blog we explain how these two types of carbon are made and what the most important differences are.
What is woven carbon?
Woven carbon is one of the most common forms of carbon composite materials. It is made by weaving carbon fibers in a specific pattern, usually in a "twill" or "plain weave" pattern, creating a textile -like material. This weaving process offers both strength and flexibility, which makes woven carbon ideal for applications where sturdy and light bendability are desired, such as in aviation, motorsport, and high-end bicycle frames.
The production process of woven carbon:
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Producing fiber: The process starts with making the basic materials: the carbon fibers themselves. These fibers are usually produced from polyacrylonitrile (pan), which is converted into carbon through a heating and combustion process. The end result is long, thin threads of carbon.
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Weave: The carbon fibers are then placed in a loom, whereby the fibers are woven into a specific pattern. The weaving can be done in different patterns, such as a Plain Weave (straight lines) or a Twill Weave (diagonal lines). The chosen pattern influences the properties of the final product, such as the strength, flexibility and aesthetics.
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Infusion or lamination: The woven carbon is usually impregnated with an epoxy resin, which seeps through the material and makes it hard. This can be done via a vacuumfusion process or by impregnating the material and then hardening in an oven. This resin binding ensures the structural integrity of the end product.
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Training: The hardened woven carbon is then brought into the desired shape. This can be done by placing it in a mold and having it harden under pressure and heat, a process known as autoclaves.
What is forged carbon?
Forged carbon, although it is also based on carbon fibers, has a completely different production process and results in a different type of material. It often has a more structured and robust appearance than woven carbon and offers various benefits, such as higher impact resistance and lighter weights in certain applications.
The production process of Forged Carbon:
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Mix carbon fibers and resin: Instead of weaving long carbon fibers, short carbon fibers are mixed with a liquid resin. This mixture forms a kind of pasta, which is then poured into a mold.
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Grind and press: The mixture of short carbon fibers and resin is then placed in a mold and pressed under high pressure. This ensures that the fibers spread throughout the mass and the material takes its final shape. The process is often carried out at high temperatures, so that the resin can harden well.
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Hardening and finishing: After the formation of the forged carbon is completed, the material is removed from the mold and curved further. This can be done by placing it in an oven or by means of another heating technique. After curing, the product is finished by sanding and polishing it, which ensures the characteristic surface texture.
Comparison: woven carbon vs. Forged carbon
Both types of carbon have their own benefits, depending on the intended application.
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Woven carbon Offers excellent strength and flexibility, and the weave structure makes it an ideal choice for applications in which aesthetics plays an important role. However, it is more vulnerable to impact and can break if it comes into contact with sharp objects or a high impact.
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Forged carbon Is more robust and offers a higher resistance to breakage in the event of impact, because the short carbon fibers are oriented in different directions. However, it is often less aesthetically attractive than woven carbon because of the loose structure of the fibers. It is often used in parts where sustainability and impact resistance are essential, such as in car or motorsport parts.
Applications of woven and forged carbon
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Woven carbon is widely used in high-end consumer products, such as sports cars, bicycles, and electronic devices. It can also be found in the air and space industry, where weight and strength are crucial.
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Forged carbon is often used in the car industry, where high performance and strength are essential under different circumstances. It is also becoming increasingly popular in the production of sports and luxury products, such as watches, tools and accessories.
Conclusion
Woven and forged carbon are both exceptionally strong materials, but the production process and the final properties differ considerably. Woven carbon offers excellent strength and flexibility, while forged carbon is more robust and more resistant to impact. Both materials find their way in different industries, depending on the specific requirements of the application. Whether you are looking for aesthetic finesse or ultimate strength, the choice between woven and forged carbon will depend on the specific requirements of your project.