Carbon Fiber Fabrication Fundamentals And Custom Solutions

Material Science And Layup Basics

Modern carbon fibers are produced primarily from PAN or pitch precursors, then oxidized and carbonized at high temperatures to align their crystalline structure. The resulting filaments are extremely strong along their axis and are bundled into tows of various sizes. Those tows are woven or stitched into fabrics like plain weave, twill, or multiaxial non crimp, each offering unique drape and mechanical behavior. During layup, fabric plies are placed into a mold with precise orientation and sequence to hit a target fiber volume fraction, since too little resin reduces bond and too much resin adds weight without strength.

Prepreg materials come pre impregnated with resin and a controlled resin content, making them ideal for high performance parts that require repeatability. Hand layup with wet resin is common for prototypes and lower volumes where flexibility matters more than cycle time. Regardless of method, clean surfaces, careful handling, and accurate ply placement are essential to avoid wrinkles, bridging, or fiber distortion that compromise strength.

Prepreg And Autoclave

Prepreg plies are laid on tool surfaces, vacuum bagged, and cured under heat and pressure. The autoclave raises temperature and applies pressure to consolidate the laminate, reduce voids, and improve surface finish. Cure cycles are tightly controlled ramps, dwells, and cool downs that activate resin chemistry and produce consistent mechanical properties.

Resin Infusion And RTM

Resin infusion uses vacuum to draw low viscosity resin through dry fabric inside an air tight stack. Variants include vacuum assisted infusion over a one sided tool and resin transfer molding with matched tools. These methods scale well, reduce emissions, and can deliver excellent fiber consolidation when flow media and venting are designed properly.

Quality Control And Testing

Non destructive methods such as ultrasonic inspection, thermography, and tap testing help reveal voids and delaminations. Destructive coupon testing confirms tensile strength, compressive strength, interlaminar shear, and open hole performance. Good process control, documented work instructions, and calibrated equipment keep results consistent across batches.

Curing, Bonding, And Machining

Composite parts cure in ovens, autoclaves, or press molds depending on resin chemistry and production volume. Epoxies dominate structural applications thanks to high temperature capability and strong adhesion, while vinyl ester and polyester serve cost sensitive parts. Out of autoclave epoxies allow vacuum only cures that still achieve low void content when bagging is optimized. Post cures can lift glass transition temperature for under hood or sun exposed components.

Joining is often done with structural adhesives that spread loads across larger areas than fasteners can. Co bonded and co cured joints improve durability by merging adhesive and laminate cure. Where bolts are required, metal inserts and carefully drilled holes with sharp carbide or diamond tooling prevent fiber pullout. Dust control is critical. Capture carbon dust at the source and protect operators since fine particles can be hazardous when airborne.

Trimming And Surface Finish

After demold, parts are trimmed to tolerance on CNC routers or with jigs and abrasive tools. Edges are sealed to block moisture ingress. Exterior faces may be clear coated for UV protection or painted for a uniform finish. High end surfaces start at the tool. A dimensionally stable, polished mold delivers the gloss and flatness that paint or clear cannot fix after the fact.

Design For Automotive Applications

Designing with carbon fiber is an exercise in directing fibers along load paths. Unidirectional plies handle tension, bias plies manage shear, and balanced quasi isotropic stacks provide predictable behavior when loads vary. Sandwich construction with foam or honeycomb cores increases bending stiffness dramatically with minimal mass gain, which is perfect for flooring, roofs, doors, and cabinetry. Thermal expansion is low and parts hold shape well under heat, though edges and penetrations need reinforcement.

In vehicles, the top use cases include aerodynamic panels, structural brackets, intake components, bumpers, roof panels, and interior trim where weight savings add up. Compared to metals, composites allow tailored stiffness and multi piece consolidation which can reduce hardware and noise. The tradeoffs are upfront tooling, careful process control, and the need to engineer for anisotropy rather than rely on isotropic properties. Cost drivers include material grade, part size, surface class, tooling material, and cycle time. Smart teams evaluate total system value, not just price per pound saved.

Sustainability is improving. Recycled fibers recovered through pyrolysis or solvolysis can feed non primary structures, and bio based resins have made strides in durability. Repairability is practical when damage is localized. Scarf repairs and bonded patches restore strength with minimal added mass when executed with proper surface prep and cure control.

When a build calls for composite components, integration matters as much as the laminate schedule. Good design ensures clearances for wiring, service access, and mounting interfaces that distribute loads into metal frames or substructures. Vibration isolation and thermal shielding protect both the composite and nearby systems. Finish quality must match the surrounding aesthetic, whether that is a raw weave under clear or a painted surface ready for adventure grit.

OZK specializes in bringing this technology into real world rigs without compromise. We design and fabricate custom composite parts that solve weight, stiffness, and packaging challenges inside complete vehicle builds. For customers planning off road travel, see our overland rigs to understand how materials and engineering turn ideas into dependable miles.

If your project needs a structural panel, an aerodynamic fairing, or a lightweight interior system, our team can blend carbon components with metal, wood, and polymer elements so the entire assembly works as one. Explore a tailored path on our custom overland upfit page for examples of integrated solutions that keep weight down and durability up. Curious about process, quality controls, and what it is like to work with us from concept to delivery? Learn more at why choose OZK Customs.

Make the next step count. Share your goals, rough dimensions, and how you intend to use the vehicle. We will review options, outline materials and processes that fit your budget, and map a clean timeline from design to handoff. Carbon fiber fabrication can unlock range, payload, and comfort when it is executed with care. Tell us what you want to accomplish and we will build toward it.