We have developed – as the first in the world – a series method for making hollow, high-strength forged carbon parts. The fibres are not cut or shortened, which preserves the strength of the part, and the part is made in one process, without bonding halves.
The challenge
Forged carbon parts are usually solid, because the C-SMC compound fills the whole mould space. Making them hollow saves mass, but the conventional solution – bonding two halves – weakens the part at the joint, lengthens production and adds machining.
Carbon Design’s scope
- Development of the method and the moulding process for hollow parts
- Design of the parts – including bicycle frame nodes – for moulding, with FEM analysis
- Design of the mould and of the inserts that form the inside of the part
- Trial batch, parameter optimisation and preparation for series production
Technology
We mould the part from forged carbon (C-SMC) in a closed volume, with vacuum in the mould cavity before and during moulding. An insert forms the inside. A patent application has been filed for the method – we discuss details with customers under NDA.
Result
- Material waste approx. 0.5% of the finished part mass
- A hollow part without adhesive joints and with minimal finishing
- A process ready for series production
- Award in the Composite Industry Innovation 2022 competition (Technology category) of the Polish Composites Technology Cluster
- We are developing the method further in the FENG project for the bicycle industry
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