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Infused Carbon Reinforced Polymer

ADVANTAGES OF INFUSED CARBON REINFORCED POLYMER

COST-EFFECTIVE PRODUCTION

Infused carbon processes, such as resin infusion or vacuum infusion, can be more cost-effective compared to prepreg manufacturing methods. This is because they often require less specialised equipment and utilise 80% less energy in the curing process.

Carbon Fusion cost effective production

REDUCED WASTE

The infused carbon process can minimise material waste since the resin is precisely controlled during the infusion process.

Carbon Fusion Reduced Waste

IMPROVED MECHANICAL PROPERTIES

Infusing carbon with certain materials, such as polymers or resins, can enhance its mechanical strength, toughness, and durability. This is particularly useful in applications where strong and lightweight materials are required, such as in the manufacturing of composites for aerospace, motorsport or automotive industries.

Carbon Fusion Mechnical Properties

DESIGN FLEXIBILITY

Infused carbon allows for more design flexibility as it can be used with a variety of reinforcements (e.g., fiberglass, carbon fibre) and resins, offering a wider range of material combinations.

Carbon Fusion Design Flexibility

LARGE PART PRODUCTION

Infused carbon is well-suited for the production of larger parts, making it suitable for applications where size and shape are crucial.

Carbon Fusion Large Part Production

GREEN CREDENTIALS

Carbon Fusion production methodology of infused carbon utilises 80% less energy than traditional prepreg carbon. In addition, with infusion 100% of the materials used can be recycled. Carbon-infused polymers, can be designed to have environmental benefits. For example, lightweight carbon fibre composites in the automotive industry can contribute to fuel efficiency and, consequently, lower carbon emissions. Large items can be produced for the benefit of the environment, such as producing carbon infused windmill blades.

Carbon Fusion Green Credentials

Infusion Process vs. Conventional 'Pre-Preg' in Carbon Fibre Composite Manufacturing

Pre-Preg Process:

  • Fibres pre-impregnated with resin in powder form.

  • Utilises extreme heat and pressure, often in an Autoclave, to liquefy and force resin into fibers.

  • Requires durable tooling to withstand Autoclave visits.

  • Limited shelf life; storage in large freezers necessary.

  • Constraints on thickness due to heat and pressure, leading to multiple Autoclave visits for a single component.

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Infusion Process:

  • Resin combined with fibres via a vacuum system.

  • Resin can be mixed with a catalyst for low-temperature curing.

  • Allows quicker and cheaper tooling production; direct heating of moulds eliminates the need for expensive equipment.

  • Liquid resin viscosity can be optimised for various component thicknesses.

  • Enables 'one-shot' infusion for large fibre-dense areas and foam core.

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