Manufacturers regularly face serious dilemmas when it comes to choosing the best materials for their projects or products. Metals are reliable and fairly affordable, but they’re quite dense and add a lot of weight and volume to the final product or component. Moreover, some tend to expand or contract when exposed to heat and cold, making them virtually useless for projects that have very narrow tolerance levels.

A way to considerably trim weight for high-performance applications is to adopt composite materials that have proven to be both lightweight and strong enough to provide solid and reliable structural integrity.

For years, there have been two popular materials competing for domination in many industries where strong yet light materials are required: fiberglass and carbon fiber. But, which one is better? Does glass fiber provide any advantages over carbon fiber panels?

Let’s find out.

What Is Fiberglass?

Fiberglass, like other composites, is also called fiber-reinforced plastic. The reason is that it is a combination of a resin matrix and millions of loose microscopic glass fibers that come from inorganic silica sand. The material is lightweight and in many ways stronger than steel. Its use expands to insulation products, boat hulls, exterior automobile parts, surfboards, and more. Most people are familiar with this material and its properties.

What is Carbon Fiber?

We have talked about this amazing composite material at length here. The main difference between carbon fiber and fiberglass composition is that carbon fiber is molecularly organized into strands that are then woven into a tow. It does not possess the randomness of glass fibers, so its strength can be directed in an immensely more predictable manner. Carbon fiber sheets or fabric is made by twisting these thin strands into yarn or tow that can contain from 3,000 to 12,000 individual carbon fiber strands. Today, carbon fiber is used extensively in many industries. From consumer goods to manufacturing, to robotics. Any product or application that requires increased performance will certainly find a use for carbon fiber products.

What Are The Differences Between Fiberglass and Carbon Fiber Panels?

There are many differences between these two composite materials but we can put them in at least four categories:

Strength

The strongest fiberglass can be stronger than steel and still be a lot lighter. That makes it great for certain applications. However, high-quality carbon fiber is more than 20% stronger than the best fiberglass on the market.

Weight

Both materials provide a lot of advantages in terms of weight-to-strength performance. However, carbon fiber weighs about 70% less than fiberglass and, given its strength, manufacturers can use far less material when pultruding products made of carbon fiber.

Rigidity

Carbon fiber panels are known for being extremely rigid while fiberglass is comparatively supple, making it more suited for applications that emphasize flexibility over durability or structural integrity. For applications that need components to retain their shape and strength, carbon fiber parts are the best choice. As an interesting fact, the Large Hadron Collider at CERN requires extremely lightweight and rigid carbon fiber structures to hold the ultra-precise tracking sensors that record subatomic particles inside the collider. They chose this material because it could be molded into extremely thin yet strong profiles that were also transparent to radiation.

Thermal Properties

Fiberglass has a small thermal expansion coefficient when compared to other metals, so it more or less retains its dimensions when exposed to heat. On the other hand, carbon fiber has a negative thermal coefficient, which means it expands as temperatures go down. However, the resin matrix that holds the fiber together has a slightly positive thermal expansion coefficient that almost neutralizes the carbon fiber panel expansion coefficient, making it a lot less prone to changes than fiberglass.

Toxicity

Here, the two materials differ greatly. Fiberglass is basically made of tiny and randomly organized glass particles. That’s why fibers that are not sealed with resin tend to irritate the skin and cause rashes even after brief contact. This is because the small glass particles are still sharp enough to cause micro-cuts, and they´re extremely dangerous if inhaled as they can also damage the lungs. Carbon fiber parts are manufactured as solid pieces that are biologically inert. This means they can be used for surgical equipment or even implants. The market is filled with orthopedic products made of carbon fiber given their safety, durability, and weight. Carbon fiber is also widely used for manufacturing training devices, sporting goods, and prosthetics.

What’s The Takeaway?

As you can see, carbon fiber offers a lot more advantages over glass fiber products. It is lighter, stronger, and safer while offering a higher aesthetic value too. The main problem many encounter is the differences in cost. However, the durability and performance of carbon fiber panels often allay material costs. If you have a project in mind and are not sure about the real advantages of carbon fiber, contact us and we will answer your questions.

The post The Real Difference Between Fiberglass And Carbon Fiber Panels appeared first on ProTech Composites.

Humans have always dreamed of flying. This recurrent vision is what motivated the Wright brothers to pursue their ambition of building a machine that was lighter than air, kicking off the aerospace industry we know today.

However, these achievements have not stopped us from wanting to experience the exhilarating physical arousal linked to heights and speed, and the freedom of fully independent flight. Indeed, engineers and tech enthusiasts continue to develop ever more sophisticated systems that bring us one step closer to achieving this undying goal.

First-person-view drones are considered the closest a person can get to flying like a bird. Once you put on your goggles and get your drone up in the air, it feels like your body has literally become a flying entity with the excitement of being free like the wind.

Now, none of this would be possible without the existence of materials that are extremely light yet strong enough to provide structural support to the components that make flight possible.

Today, there are many kinds of drones, but the fastest and most agile ones out there leverage the advantages of custom carbon fiber parts. Manufacturers or drone component providers are constantly kept on their toes, always trying to offer the lightest and strongest drone frames and battery packs, or the most efficient motors and rotors. But competition is fierce and many players will never rest until they design the ultimate drone.

This incessant pursuit is mainly driven by two unstoppable forces: the desire to push drone building to the limit, and the relentless determination of FPV drone racers.

FPV Drone Racing As A Sport

While radio-controlled vehicle racing has been around for years, it never reached the status of a sport. However, FPV drone racing is changing the way people think about sports. and the necessary skills an operator must have to pilot one of these birds at incredible skills through mind-bending courses.

Some place the beginning of drone racing back in 2011. A bunch of misfits and daredevils got together in Karlsruhe, Germany, and organized a series of races and challenges. Word got out, and thousands of tech enthusiasts around the world wanted their version of Karlsruhe.

Today, there are hundreds of drone racing teams and leagues that now run their own course. The prize pool in some of these events can be quite hefty, which in turn attracts more competitors, manufacturers, crowds, and, of course, sponsors.

What makes drone racing different from most competitions is how courses and challenges are designed. Traditional races are held in mostly two-dimensional arenas. With the exception of some winter sports, most tracks are quite horizontal in shape.

FPV drone racing courses are three-dimensional. Meaning that drones must race through what can be aptly described as a roller coaster track. They need to take tight corners at amazing speeds, climb as fast as they can through vertical tunnels, drop from incredible heights and stop on a dime, and then go from 0 to 100mph in two seconds.

This kind of nimbleness cannot be achieved through raw power alone. Technology today can produce incredibly powerful engines that give speed and momentum to sportscars and can put men on the moon. However, when compared to competitive FPV drones, those engines are heavy, unwieldy, gas-guzzling dinosaurs.

In 2019, a drone racing pro told BMW how drones were superior to the best sports cars out there. According to drone racing champion Andreas Hanh, high-performance drones are not as fast as sports cars in terms of top speeds, but they can take tight corners at maximum speeds and accelerate from zero to 100 mph almost instantly.

The best part about this sport is that pilots see everything from a first-person perspective. When they put on their FPV goggles, they feel the drone is part of their bodies. This means they feel the rush associated with flying or driving at devilish speeds but must also develop extremely fast reflexes to safely control their machines.

No wonder many of the best pilots out there come from the videogame world. Their skills make them natural in this highly competitive arena, and they are used to playing with highly complex simulators and racing games. However, pilots must also have extensive knowledge of electronics and engineering. This helps them keep their machines in top condition, but also tweak them so they adapt to their flying style. Here is where custom carbon fiber parts play a decisive role in the sport.

Carbon Fiber Drone Frames and Components as Sports Equipment

Now that FPV drone racing is officially a competitive sport, custom carbon fiber parts are in high demand by teams around the world.

It is no secret that custom carbon fiber parts are now ubiquitous in sports that benefit from high-performance materials to achieve increased speed, enhanced durability, and more efficient use of energy. This includes faster and more energy-efficient sports cars and racing bikes, lighter and stronger tennis rackets and golf clubs, and stiffer and more durable snowboards and skis.

Big companies are pouring money into drone racing too. ESPN and Discovery Channel have been covering official FPV drone racing events for years now, and corporate sponsors like Pepsi, GoPro, and Airbnb, all have official teams interested in developing drones that fly faster, are more agile, and are able to last longer at top speeds. This requires the utilization of lighter materials that can also withstand high-speed crashes without getting a machine out of the race.

Of course, the quality of the fibers they use will affect the overall performance of their drones and components. They need the right tow size and elastic modulus depending on the part requirements, but also the correct resin matrix for durability, strength, and weight.

That’s why specialized makers prefer partnering with carbon fiber manufacturers that understand the specific needs of drone racing. If you´re looking for custom carbon fiber parts or high-performance raw materials for your commercial or competitive drones, contact one of our experts today.

The post Why Custom Carbon Fiber Parts Are The Future Of FPV Drones appeared first on ProTech Composites.

Carbon fiber is easily one of the most impressive materials on the market today. In more recent years, it has exploded in popularity, as it can be used as an especially practical and effective material in a vast number of industries, including:

• Aerospace
• Aircraft (airplanes, helicopters, jet planes, etc.)
• Race cars and automobiles
• Drones or UAVs
• Manufacturing
• Knife scales
• Robotics
• Medical
• Electronics

Surprisingly, the above list isn’t even comprehensive, as carbon fiber can appear in nearly any industry, but these are where it is the most prevalent and applicable.

Carbon fiber cutting is a preliminary and necessary step in utilizing this unique material. However, while it may seem like an easy task to complete, it isn’t always so because it’s lightweight yet extremely strong. On top of that, there are specific tools that you need to get the job done efficiently, safety precautions to take, and the correct cutting tools to properly cut the material.

Safety Tips for Carbon Fiber Cutting
When carbon fiber is being cut, the process can lead to the expulsion of carbon fiber dust. Fortunately, carbon fiber dust isn’t toxic. However, it can be relatively abrasive and the cut panels can be quite sharp.

In order to keep your skin safe from irritation, cuts, and scrapes, we recommend that you wear gloves, long-sleeved shirts, and long pants (especially those made of wool or cotton). This dust can also cause irritation to your lungs and your eyes, so wearing safety goggles and a dust mask is extremely important as well. If you are using power tools, you should wear hearing protection, too.

Carbon fiber dust is known to be conductive. With that in mind, be sure that you are far away from electronic devices because this dust can cause damage to them and even lead to a shortage in an electrical circuit. Opt for a well-ventilated location as well and always remove your jewelry.

For disposal of the waste, use a shop vacuum cleaner or quality vacuum system when you’re sanding or cutting carbon fiber. As for your scraps, you should find a recycling service specifically for carbon fiber and use that for the best and safest disposal practices (carbon fiber isn’t biodegradable, so putting it in with your household or shop trash isn’t ideal).

General Tools and Aids to Prepare

As the case is with any project, you should prepare all of your tools and other aids ahead of the actual beginning to have peace of mind and lowered stress. Some items you should have ready to go include:

• A measuring tape: to ensure even cutting (remember: measure twice then cut once!)
• Backing material: try using wood or rigid foam to decrease the likelihood of backside blowout and help in achieving best results
• A marking tool: a metallic Sharpie is one of the best options for marking on carbon fiber. You can remove stray marks with acetone later. If you don’t have a metallic Sharpie, you’ll need masking tape, then a pen or pencil to write over that
• Painter’s tape: to increase precision and to know exactly where to cut

And, of course, you’ll need the tool(s) you’ll be using to physically cut the carbon fiber– and that brings us to our next point.

Best Ways to Cut Carbon Fiber By Hand
There are essentially two types of tools you can use for carbon fiber cutting: manual tools and power tools. Both types have their very own advantages and disadvantages but overall can cut your carbon fiber perfectly well when used correctly.

Scissors and Razor Blades
If your carbon fiber is .5mm or less in thickness, then it is perfectly fine to use scissors or razor blades to cut it. Steer clear of shears or scissors that have ridges or teeth, as these can actually cause cracks in the epoxy resin. However, beyond that aforementioned thickness, you should consider other cutting tools and techniques.

Check out our list of standard carbon fiber thicknesses which also lists key cutting tools and other information for them.

Hand Saw
A hand saw is one of the most classic and cost-effective tools for cutting carbon fiber yourself. The blade can dull rather quickly, but for the sake of your purposes, it is perfectly fine to use. Try a hand saw that has a higher TPI (teeth per inch) in order to get the best cuts possible.

Rotary Tools (Especially Angle Grinders)

And now for power tools, starting off with rotary tools and angle grinders more specifically. Angle grinders are impressively versatile electrical tools that are used to cut, sand, grind, sharpen, and polish a variety of materials– one of which is carbon fiber. This power tool is especially ideal because of its fast rotations, which lead to more accurate cuts in carbon fiber.

Rotary tools are exceptional power tools to use on carbon fiber because of their high RPM (rotations per minute), as briefly touched upon above. Dremels are also great options and will provide you with even more precise cuts than angle grinders, especially for smaller projects.

You should keep in mind that carbide, abrasive type cutters, and diamond-crusted tools are overall the best options because regular steel tools work well yet can wear down quickly.

CNC Machines
If you have access to CNC (computer numerical control) machines and know how to operate one efficiently, you can also use these to cut your carbon fiber sheets. However, sometimes holding the carbon fiber sheets can be uncomfortable and lead to poor cuts.

Water Jet Cutters
Water jet cutters are excellent options for cutting carbon fiber because they can cut those hard-to-reach nooks and crannies and create complex shapes. They also offer you increased control over the cutting surface.

Now that you have a far better understanding of carbon fiber cutting and what goes into it, you may be wondering if it’s worth it to seek outside assistance with cutting this material. Keep us in mind for your next cutting project, as we have CNC machines that are operated by our professionals to give you clean-cut carbon fiber.

The post Everything You Need to Know About Carbon Fiber Cutting appeared first on ProTech Composites.

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In other words, it is often impractical to use composites for products or parts that do not necessarily benefit from carbon fiber´s incredible properties. However, the recognizable woven pattern and its deep black colors have a special aesthetic appeal that many associate with high-quality or premium products, making it an attractive texture to imitate as it adds to the subjective value of certain items and sometimes even grants added structural benefits.

Many have tried to replicate the looks of carbon fibers using vinyl sheets and other common materials for wrapping. However, these tend to look fake, chip away easily, and show signs of deterioration very quickly. That’s why many shops have adopted carbon fiber veneer as their go to material for performing carbon fiber skinning.

Skinning or wrapping is the process of changing the look of a product or piece with a thin layer of protective material. This is usually done to enhance the appearance of your product, but can also add certain protective properties depending on the material. As a wrapping technique, carbon fiber skinning deserves its own chapter in the books for being such a unique process that produces such distinctive results. It delivers eye catching textures, and adds a level of protection and strength only carbon fiber can offer, going way beyond a mere cosmetic improvement.

In the automotive industry, it is not uncommon to see cars with parts made of carbon fiber, especially the hood, skirts, bumpers and spoilers. However, there are other parts that do not benefit from the properties of carbon fiber, or that do not make sense in terms of cost-effectiveness. Car owners choose to use carbon fiber veneer to wrap these parts and give their vehicles a uniform and smooth look. Many also choose to apply carbon fiber veneer to the car interior to add a polished and modern look to their ride. The way carbon fiber is woven reminds some of muscle tissue which represents strength, others associate it with the glamour of high performance racing, which is not far from being true.

A skillfully done wrap using high-quality carbon fiber veneer is impossible to differentiate from a solid piece or part made from carbon fiber.

One great advantage of using carbon fiber veneer is that it protects your parts from abrasion, scratches, and even UV damage. Among the most common objections people have for wrapping or skinning their vehicles, is that UV rays tend to damage the finish over time. In order to wrap a part or product with carbon fiber veneer, it must be combined with a resin that bonds carbon fibers with the part. Using the incorrect resins might cause the finish to degrade over time. In order to choose the right sheets and resins, we recommend contacting us to find out which product will provide the best protection and performance for your project.

Other products in the outdoor sports industry also benefit from carbon fiber skinning. Many hunting enthusiasts enhance the look and feel of their instruments by adding carbon fiber veneer, which also protects them from the elements without adding extra weight or bulk. In many cases, carbon fiber veneer adds strength to the part or instrument being treated, offering great support and structural resistance to vital pieces.

This is especially true for board sports. Wrapping a skateboard deck with premium carbon fiber veneer changes the board´s properties, making it slightly more rigid yet resistant to tensile forces, without the problems associated with solid carbon fiber boards such as delamination or microcracks.

However, the versatility of carbon fiber veneer does not stop there. Many manufacturers have caught on with market preferences and now offer incredibly practical accessories cleverly wrapped in carbon fiber. We can find wallets, phone cases, suitcases and other consumer goods that take advantage of the properties of this incredible material, adding aesthetic value to their high-quality products.

If you have a project that requires high-quality and durable carbon fiber veneer, or want to know more about the properties of this incredible material, get in touch with the sales team at Protech Composites. We provide carbon fiber sheets in various thicknesses depending on the properties of your product and their uses, and can guide you through our product line so you can find exactly what you need for your project.

The post What Is Carbon Fiber Skinning? appeared first on ProTech Composites.

Well, thirty years have passed, and we still use the same old materials, while flying cars are nowhere to be seen. Nonetheless, we do see a ton of molded carbon fiber parts in machines or objects we never imagined would benefit from this material. Still, the way it is made, and its amazing properties, represent an enigma for many, mainly because making it requires a complex and costly process.

Why Is Carbon Fiber So Expensive?
History dictates that, as technology advances, manufacturing techniques get more efficient, and products get cheaper. However, this has not happened with carbon fiber manufacturers, or at least not as fast as we would like.

The fact is it takes a lot of effort and energy to make composite materials. Carbon fiber does not exist in nature. While its components do, the properties of molded carbon fiber parts come from the combination of completely different elements that have very distinctive traits that we deem desirable, especially for specific applications.

Carbon fiber is extremely rigid and lightweight. A finished carbon fiber part can be a lot stronger and lighter than equivalent metal or plastic parts. This is why it is often used in planes, cars, and other high-end applications. However, many manufacturers have adopted carbon fiber for more day-to-day items, such as golf clubs and wallets.

The manufacturing process of carbon fiber involves combining these incredibly thin, yet remarkably strong, strands with an epoxy resin. The result is a material that is extremely strong and stiff, but also lightweight enough to represent an advantage for high-performance products and parts.

The stiffness and lightness come from two features of carbon fiber, the components, and the “cure”. The components are the strands of carbon fiber filaments thinner than human hair and composed of carbon atoms of about 5-10 micrometers in diameter.

Carbon is an incredibly peculiar material, and one of the hardest elements in nature. It is the sole constituent of diamonds, the hardest natural substance, but also a vital component of graphite, one of the softest materials in existence. The differing properties come with the way carbon atoms arrange themselves. Their properties change depending on the way atoms bond with each other.

Carbon fibers are incredibly thin strands that have amazing tensile strength, and a properly made carbon fiber filament can be stretched up to three times its original length before breaking. They are spun and woven into a cloth-like texture with the all-too-familiar checkered texture carbon fiber enthusiasts have come to love.

However, you cannot make pieces of carbon just by stuffing carbon sheets into a mold. You need to bind the threads together into shape by using a component that acts like a glue. The combination of these two materials is what gives us the famed strength-to-weight ratio of carbon fiber parts.

The “cure” is the process of hardening or curing a resin that covers the carbon fiber strands. Epoxy is a thermoset resin, which means that it crosslinks and hardens when it is exposed to heat and/or pressure. This reaction is what creates the final product, so controlling the cure is essential to ensuring the quality of the carbon fiber part.

For example, when crafting high-strength parts such as aftermarket car parts or aerospatial application products, the epoxy is usually applied through injection molding. Carbon fiber manufacturers create a mold with the specific shape of the finished part, then carefully place the carbon fiber sheets inside and proceed to inject the epoxy into the sheets. Then, the mold is treated with heat, vacuum, or pressure, depending on the epoxy used or the results you are after. We will cover the curing process in detail in a future entry.

Other carbon fiber manufacturing processes only require wrapping a mold or part with sheets and “painting” it with epoxy. It is a long process that requires several iterations and the application of correctives along the way.

But the purpose of curing is to provide a stiff and cross-linked matrix with the finely woven carbon fiber threads. This is what ultimately grants this super material its strength and rigidity. The final product is light but incredibly strong! This makes it the perfect material for a variety of applications; from aircraft parts to bike frames.

Why Isn’t Everything Made Out Of Carbon?
Many carbon fiber manufacturers today dominate the art of creating carbon fiber products. This composite is incredibly versatile and can be molded and weaved into endless forms. So, why don’t we have carbon fiber mugs, chairs, keyboards, and even houses?

Explaining the process of making carbon fiber in a single article, without allowing you to take a peek inside the mad hatter’s shop, would make it seem like an easy material to manufacture.

The reality is that it is an extremely complex process that is not easily scalable. The cost of precursors, the elements used as raw materials, is relatively high. The process of creating the long strings of carbon atoms and achieving the right tensile strength, and then weaving them into resistant and flexible structures is extremely resource-intensive. Then carbon fiber manufacturers need to mold, curate, cut, and machine their carbon fiber into finished parts, and this takes a lot of skill and experience to get every part of the process right.

The complexity of the process means that there are many ways for things to go wrong, and a lot of trial and error is needed to produce high-quality carbon fiber parts. This makes it important to only buy carbon fiber products from composite providers who can guarantee top performance materials for your projects while keeping costs competitive.

Protech Composites helps carbon fiber manufacturers of all sizes and industries discover new ways carbon fiber can elevate their product´s performance and style.

The post What Makes Molded Carbon Fiber Parts So Special? appeared first on ProTech Composites.

How Is Carbon Fiber Made?
All carbon fiber suppliers start the manufacturing process in the same basic way. Carbon fiber panels, fabric, sheets, and all other products are made from a collection of carbon fiber strands that are thinner than a human hair.

These fibers are made from a polymer precursor material known as PAN (which stands for polyacrylonitrile and contains carbon). This is a plastic that is spun into very fine fibers, then washed and stretched to a very fine diameter that helps to ensure that the carbon fiber crystals it contains are very tightly bonded.

These fibers are then heated in an oxygen-controlled environment, which adds oxygen to the fibers, changing the bonding structure from linear to ladder-shaped. This is known as a cross-linked polymer, and this form of bonding is one of the reasons that gives carbon fiber such high strength, high flexibility, and overall high performance.

After this, the fibers are heated again, this time in an oxygen-free environment that forces all of the impurities from the matrix, leading pure carbon fiber behind. After this process, all that remains are tightly-linked carbon crystals that are exceptionally lightweight and strong.

These carbon fibers can then be wound into collections called Tows before being woven into sheets. The next step is where the issue with UV light arises.

These pure carbon fibers themselves are not only UV stable; they are effectively UV-impervious. So, in one sense, to answer the question “is carbon fiber itself UV-stable?” the answer is yes.

However, after being woven into sheets or panels, the next step in the process is to add epoxy resin.

Why Do Carbon Fiber Suppliers Add Epoxy Resin to the Carbon Fiber Matrix?
Carbon fiber manufacturers add a special material called epoxy resin to carbon fiber sheets and panels for several reasons. One is that epoxy resins are one of the few materials that will both penetrate and adhere to carbon fiber.

Another is that epoxy resin makes carbon fiber stronger. It reinforces the weave with dimensional stability when stresses, such as compression, torsion, or shear forces are applied. It also fixes the fibers in a specific geometric arrangement. This prevents misplacement of the fiber tows that can weaken the matrix.

Another reason is aesthetics. Because the resin fixes the fibers in place, it prevents a cosmetic disruption of the weave. The epoxy resin is also responsible for the high-gloss finish of many carbon fiber products. Unfortunately, some epoxy resins are not UV-resistant.

What Dangers Does UV Light Pose?

Ultraviolet, or UV light, is a form of electromagnetic radiation with wavelengths just beneath those of the visible spectrum. It is comprised of three main types: UVA, UVB, and UVC light, in order of descending wavelength, from 400nm to 100nm.

UVC light is the most damaging of these wavelengths and causes irreparable cell damage. This is also the wavelength that is responsible for most damage to certain other organic materials. For example, UV light can cause damage to certain synthetic polymers, such as PVC and certain rubbers. They become discolored and brittle with UV exposure and can even crack or crumble. This is known as UV degradation and it is a real challenge for synthetic materials producers.

UV light can also damage the epoxy that binds carbon fiber products. With prolonged exposure to UV radiation, the chains of polymers within the epoxy will break down, causing yellowing, fading, cracking, and crumbling.

While the UV light does not destroy the carbon fibers themselves, it can cause the premature degradation of sheets and panels by degrading their epoxy resin. In this respect, not all carbon fiber products are UV stable.

What Can Be Done About It?

Luckily, many carbon fiber suppliers use UV-resistant epoxy resin to finish their carbon fiber products. We are one of them.

We use a vacuum infusion process to inject the carbon fiber with UV-stabilized epoxy with a low density and high compressive strength. This actually strengthens the carbon fiber composite matrix without adding very much weight. It also gives it an added layer of resistance to UV radiation.

For these reasons, products that are made with UV-resistant carbon fiber are suitable in many of the following industries in which exposure to sunlight is inevitable:

• Aerospace and engineering
• Automotive parts and accessories
• Marine parts
• Sporting goods and accessories
• Medical equipment
• Robotics and manufacturing
• Consumer goods, including knives and other products for outdoorsmen

Fading, yellowing, and cloudiness are common signs of UV damage, and to some degree, with enough exposure to the elements, all carbon fiber will experience some UV damage.

Whether your carbon fiber is made with UV-stable epoxy resin or not, it may be possible to restore it.

If your carbon fiber has no cracks and is only slightly yellowed or faded, you may be able to sand off the damaged epoxy and re-apply a fresh clear coat.

Use only very high grit sandpaper to prevent removing excess stock. Sand very lightly, and pay attention to the color of the dust; epoxy dust will be brownish, white, or yellowish. If it’s gray or black, stop immediately. This means you’re sanding too deep and are damaging the carbon fiber.

Once you’ve removed the layer of epoxy that was damaged by UV, apply a new clear coat finish to restore its high-gloss appearance.

Carbon Fiber Questions? Call Us!
We are your source for high carbon fiber products for the automotive, aerospace, medical industries, and many others. We stand by our products and offer a 100% satisfaction guarantee. If you’re considering a project that involves the use of the finest carbon fiber products in the composites industry, please contact us!

If you are interested in learning more about our cutting-edge, high-quality carbon fiber products and composite materials? Feel free to consult our carbon fiber resources or get in touch with our customer service team directly at 300-573-7800.

The post Is Carbon Fiber UV Stable? What You Need to Know appeared first on ProTech Composites.

Other carbon fiber manufacturing companies might offer differing advice on what you can use to cut carbon fiber sheets or panels (given thickness, weave, the type of epoxy resin used, and more). However, some tools are better than others for the purposes of cutting carbon fiber. They can be broadly classified into hand tools and power tools.

Manual Tools: Bladed Tools (Scissors, Shears, Razor Blades)
Thin carbon fiber sheets can be cut with basic bladed cutting tools like scissors, razor blades, and even shears. We recommend using the sharpest possible tools because these will make the cleanest cuts. Avoid heavy tin snips and shears with ridges or “teeth.” These leave clean cuts in sheet metal but can cause cracks and leave stress risers in the epoxy resin of carbon fiber panels.

Power Tools: Abrasive Cutting Wheels (Angle Grinders)
Angle grinders equipped with metal cutting wheels can be highly effective tools for cutting through carbon fiber quickly and efficiently. Power tools like these can be highly effective at cutting carbon fiber because they oscillate much more quickly than hand tools and produce a clean, accurate cut.

Power Tools: Rotary Tools
Even high-quality rotary tools such as dremel tools are not as powerful or as large as angle grinders, but because of their smaller size and easier maneuverability, they can be used for making very precise cuts and alterations to carbon fiber panels. We recommend solid rim cut-off disks.

These are probably the most versatile tools overall for cutting carbon fiber products. Use metal cutting discs to make clean cuts in the carbon fiber, on the highest speed setting safe for use with the disc. These tools are also useful because most rotary tools operate at such high RPM that imperfections in the edge or on the surface of carbon fiber panels or sheets can be rectified with very fine sanding or buffing bits.

Why High-Speed Is a Good Thing
We suggest using either a rotary tool or an angle grinder for making cuts to carbon fiber because these operate at high RPM and with precise handling, can be used to make very clean cuts without ripping, cracking, or stressing carbon fiber.

However, it is important to note a few things. One is that carbon fiber is highly abrasive to cutting edges. Whether you use a craft utility blade, or metal cutoff disc to make cuts, you’ll need to replace it frequently because the cutting edges will probably wear quickly.

The other is that you should also wear personal protective equipment when cutting carbon fiber, regardless of whether you use hand tools or power tools. Always wear safety glasses and gloves to adequately protect your hands. Remove all jewelry. We recommend wearing long-sleeved clothing and long pants made from natural fibers, like cotton or wool. If you’re cutting with power tools, use hearing protection as well. Wear close-toed shoes or work boots.

Another common question is whether or not carbon fiber is dangerous, which merits its own brief investigation.

Is Carbon Fiber Dust Dangerous? (And a Primer on PPE)
While carbon fiber dust is not toxic, the fibers can be abrasive and the edges of cut panels can be sharp, producing mild irritation to the skin of sensitive individuals. This is why we recommend adequate protection for your hands as well as long sleeves and pants. We recommend wearing a dust mask to prevent accidental inhalation as well. It’s not toxic, but it can be a mild irritant, so you don’t want it on your skin or in your eyes or lungs.

However, carbon fiber is a conductive material, and therefore you should take care to protect sensitive electronics from exposure to its dust. Always use a good vacuum system or shop vac when cutting or sanding. Choose a well-ventilated area away from electronic devices, as exposure to carbon fiber dust can cause a short in an electrical circuit.

Trust the Quality of a Premier Carbon Fiber Manufacturing Company
High-strength, high-performance carbon fiber composite raw materials are vital to the manufacturing processes in many industries, such as automotive, aerospace, defense, sporting goods, in the medical field, and elsewhere.

So are the right cutting tools and techniques. Protech Composites is a carbon fiber manufacturing company that produces high-quality composite materials that will benefit from proper handling, cutting, and shaping. If you have any questions about our carbon fiber products or what tools or techniques would be best used to cut them given your precise application, please reach out to our customer service team at 360-573-7800.

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Carbon fiber is both a strong and lightweight polymer used in a wide range of applications, from aerospace and aircraft to the manufacturing of toys, golf clubs, and knife handles. It is five times stronger than steel but is just one-third of its weight.

Carbon fiber is a unique and necessary component in countless industries today. While the present forms and usages of carbon fiber are of particular interest, it’s worthwhile to consider the impressive history of the material along with its proposed future. Let’s take a look at carbon fiber’s past, its brilliant present, and its bright future.

Carbon Fiber: Its Surprising Beginnings
Carbon fiber was first invented back in 1860 by a man named Sir Joseph Wilson Swan. Swan was an English inventor, physicist, and chemist who was the early independent developer of the first incandescent light bulb.

Swan had invented carbon fiber in order to use it within an early version of the incandescent light bulb’s filament. He used carbon fiber because its high heat tolerance was ideal, making it a superb electrical conductor. His process of creating carbon fibers for his filaments was so meticulous and impressive that it is still being used by polymer chemists to this very day.

Swan’s lightbulb with a carbon fiber filament was used as a base for Thomas Edison’s patented lightbulb twenty years later. Edison created his light bulb, then patented it in the United States and advertised that he was the inventor of essentially Swan’s invention. In the end, the two compromised: in England, they established the “Edison & Swan Electric Light Company” (a.k.a. “Ediswan”), and in the USA, Edison was given the rights to produce electric lighting.

Eventually, however, the carbon fiber in these filaments was replaced by tungsten, and carbon fiber was rendered obsolete for the next fifty years. It wasn’t until the 1950s when Union Carbide started toying with carbon fiber applications, especially for the military, that it became popularized. From the 1950s to the 1970s, the material was altered and molded to become far more useful.

Carbon Fiber Today

Today, carbon fiber in its numerous forms is found in a slew of products, big and small, and of varying applications across the globe. Carbon fiber scales, for one example, are utilized as the primary material in knife handles. Carbon fiber sheets are used in numerous industries, such as in automobiles, aircraft, robotics, medical, drones, and consumer products.

Carbon fiber fabrics also come in numerous weaves, which therefore affect their appearance and functionality. A 3k fabric, for one example, has 3,000 strands of carbon fiber fabric. Carbon fiber sheets (or composites) are created from these fabrics.

Carbon fiber scales, sheets, fabrics, and other variants provide countless advantages to the overall product in which they are used. It is exceptionally lightweight in comparison to its level of strength, has a low thermal expansion, is resistant to corrosion, is electrically conductive (just like it was when it was first invented), and is even resistant to ultraviolet light.

Today, carbon fiber is found in countless products, some that we use daily and some that we use on very specific occasions. Carbon fiber is found in items like bicycles, golf clubs, softball and baseball bats, spacecraft, wind turbine blades, vehicles (even racecars), umbrellas, electronic devices, cell phone cases– the list goes on and on.

What’s in Store for Carbon Fiber in the Future?
The future of carbon fiber is exciting and is continually evolving. Carbon fiber is an undeniably and remarkably versatile material that could even last a lifetime in the right conditions. However, there are some current issues with carbon fiber that look to be altered in the future for our betterment.

One of the most major issues that befalls carbon fiber is its cost for manufacturing. In fact, it is one of the most expensive highly-durable materials to create. However, there is hope for carbon fiber in the future in this regard, as the price for it has drastically decreased in the last five years alone as carbon fiber in all of its forms has increased in popularity.

The next few decades in particular look to provide us with carbon fiber that is easily accessible, more cost-effective, and still extremely reliable, strong, and lightweight.

Purchasing Carbon Fiber for Your Business
Carbon fiber is no doubt a material worthy of extreme merit and even consideration for nearly any business. When you are looking for the most reliable carbon fiber scales, sheets, and more for your desired goals, work with us here at Protech Composites Inc. where we guarantee no pinholes, voids, or porosity ever because your satisfaction is our satisfaction.

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When you are looking for materials to use in your business’s products, you need to supply yourself with the sturdiest, most reliable, and most applicable components possible.

As you might already know, that is significantly easier said than done.

Amongst the many possibilities for product materials, one stands out above them all in composition and overall reliability: carbon fiber.

Before we dive headfirst into explaining optimal utilization of carbon fiber across numerous industries, let’s briefly break down what carbon fiber is along with what makes it so highly sought after and so highly versatile.

What Is Carbon Fiber?
Carbon fiber is a polymer, specifically a synthetic fiber, that is both exceptionally sturdy and lightweight. Carbon fiber is ten times stronger and 5 times lighter than steel and 1.5 times lighter than aluminum.

Carbon fiber can vary in size and thickness. For just one example, one carbon fiber tow can be even thinner than a human hair! Carbon fiber parts are typically comprised of carbon fibers strategically interwoven, which provides the final product with unequivocal strength. Carbon fiber can be laid over a mold then coated in plastic or a resin, resulting in various sturdy parts.

How Is Carbon Fiber Made?

The creation of carbon fiber is meticulous and involves both chemical and mechanical processes. First, fibers are laid out and heated at a very high temperature, usually near 1800°F/982°C. The fibers are deprived of any oxygen exposure in order to keep them from burning.

This high heat process is where carbonization occurs, which essentially means almost all atoms are expelled from the fibers except for carbon. What then results is tightly-locked carbon atoms with only a small amount of other atoms present. The result is carbon fiber tows that are bundled together and woven into fabric in different weights and weave patterns.

What Are the Benefits of Using Carbon Fiber?
As mentioned above, carbon fiber exemplifies numerous qualities most manufacturers of various products are looking for, such as strength, lightweight, and versatility. It also provides them with a material that has high chemical resistance, high tensile strength, is exceptionally tolerant of excessive heat, and has low thermal expansion.

Carbon Fiber in Various Industries
But how exactly are carbon fiber parts utilized in various industries? In short, a multitude of ways because carbon fiber is truly an impressive and adaptable material. Let’s take a closer look at the industries in which carbon fiber is utilized the most often and where it can be applied for optimal performance.

Knife Manufacturing
The manufacturing of sturdy and reliable knives is quite heavily reliant on carbon fiber, more specifically the manufacturing of knife handles. Knife handles are made of various materials, some of the most popular being carbon fiber, micarta, G-10, several natural materials (wood, bone, antler, etc.), aluminum, fiberglass reinforced nylon (FRN), and titanium.

Carbon fiber is one of the most reliable materials for knife materials because of it’s chemically stable, light, strong, and not absorbent. It also provides each knife it’s used in with a premium appearance and feel.

Robotics
When it comes to robotics, there are only a handful of materials that can be effectively utilized, such as steel, rubber, aluminum, and carbon fiber. Carbon fiber supply robotics with exceptionally strong parts to allow for seamless mobility, automation, precision, motor skills, and other tasks.

Plus, carbon fiber provides robotics with necessary lightweight components so that it can have overall increased performance and reliability.

Manufacturing of Consumer Products
When it comes to manufacturing products, not all materials are built the same. Sometimes, common items that are used in the manufacturing industry, like aluminum, steel, and plastic, simply won’t cut it.

Carbon fiber can properly be included in the manufacturing process to supply products with unparalleled durability, strength, and lightweight capabilities. This unique material might just be the saving grace in the manufacturing process for countless products, as it finally provides them with the qualities many products require, whether they be boats or toys.

Aviation
When it comes to creating aviation products, having sturdy and reliable components is undeniably goal number one during design and development. This is because every aircraft, whether it be an airplane or a spacecraft, needs to be able to withstand various temperatures and high-pressure conditions without a semblance of potential failure or error.

Carbon fiber parts are found in various sizes and applications in nearly all aviation vehicles, including military aviation crafts, in objects such as large panels and gauges along with smaller switches and support screens.

Drones/UAVs

Much like larger aviation vehicles can reap the benefits of carbon fiber parts, as can the smaller ones, such as UAVs (unmanned aerial vehicles). UAVs require carbon fiber in order to effectively and efficiently accomplish all of the tasks that are necessary, which include taking off, flying, making sharp turns, hovering, and withstanding numerous weather conditions while airborne.

Carbon fiber can be found in nearly every inch of drones, specifically the rotor and fixed wings. This is because these components, among the many, require this particularly versatile material for proper strength, corrosion resistance, and lightweight features.

Medical
When it comes to our health, we deserve only the best and high efficiency– and that includes the various pieces of equipment and devices that allow for diagnosis, treatment, and other healthcare processes. That is precisely why carbon fiber is also readily used in the medical industry.

Carbon fiber can be found in large pieces of equipment, such as MRI and x-ray machines, but also in more practical applications for day-to-day life for some patients, such as prosthetic limbs. Since there is an exceptionally low tolerance for error in this industry, only the most reliable of materials are allowed, hence the high prevalence of carbon fiber.

Where to Purchase the Best Carbon Fiber Parts
As seemingly perfect as carbon fiber can appear, there are common issues that befall it when there are poor creation tactics used. Some of these issues include porosity, voids, and pinholes. That is why you should purchase high-quality carbon fiber from the most reputable carbon fiber parts manufacturer, which is us here at Protech Composites.

We guarantee that none of our carbon fiber parts, sheets, and other carbon fiber products have such issues so you can purchase and utilize them with the utmost confidence. Give our dedicated and knowledgeable customer service team a call today at 360-573-7800 to get started on your next project!

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