How to Produce Carbon Fiber Plates from Carbon Fiber Fabric: A Step-by-Step Guide

Producing carbon fiber plates from carbon fiber fabric involves a series of precise steps to ensure optimal strength, rigidity, and durability. Below is a detailed breakdown of the process, accompanied by reference image links for each stage.
 

1. Preparation of Carbon Fiber Fabric

Process: Carbon fiber fabric is woven from carbon fiber filaments, which are derived from polyacrylonitrile (PAN) precursor fibers through oxidation, carbonization, and surface treatment. The fabric is typically pre-impregnated (prepreg) with epoxy resin to enhance bonding and handling during subsequent steps.

• The fabric’s weave pattern (e.g., plain, twill) affects mechanical properties and aesthetics.
• Prepreg materials are stored in controlled environments to prevent premature curing.
  

2. Layup and Stacking

Process: Multiple layers of carbon fiber fabric are stacked in a mold according to the desired thickness and fiber direction. Each layer is aligned to optimize strength in specific directions (e.g., 0°, 90°, ±45°)

• Automated cutting machines ensure precise fabric dimensions.
• Vacuum bagging may be used to remove air bubbles and ensure uniform resin distribution.

3. Resin Infusion or Prepreg Curing

Process: For non-prepreg fabrics, resin (e.g., epoxy) is infused into the stacked layers using methods like vacuum-assisted resin transfer molding (VARTM). Prepreg materials, however, undergo controlled heating in an autoclave to cure the resin

• Autoclave curing applies high pressure (up to 100 psi) and temperature (120–180°C) for uniform consolidation.
• Curing cycles are tailored to resin specifications to prevent voids or delamination.

4. Trimming and Finishing

Process: After curing, the carbon fiber plate is removed from the mold and trimmed to final dimensions using CNC machining or waterjet cutting. Surface finishing (e.g., sanding, polishing) is applied for aesthetics and functionality

• Precision cutting minimizes fiber fraying.
• Edge sealing may be required for moisture resistance.

5. Quality Inspection

Process: The final plate undergoes non-destructive testing (NDT), such as ultrasonic scanning or X-ray inspection, to detect internal defects like voids or cracks. Mechanical testing (tensile, flexural) ensures compliance with industry standards.

• ASTM D3039 and D7264 are common testing protocols.
• Surface coatings (e.g., UV-resistant) may be applied for outdoor applications.

References