The Manufacturing Process
The production of carbon fibre is a complex chemical and mechanical process that transforms organic polymers into strong, durable fibres. The majority of carbon fibres—around 90%—are made from polyacrylonitrile (PAN), while the remaining 10% come from rayon or petroleum pitch. The process consists of several critical stages:
Before carbonisation, the precursor fibres (usually PAN) must be stabilised. This involves heating them in air at 200-300°C for 30 to 120 minutes. During this stage, the fibres undergo oxidation, allowing oxygen molecules to attach to the atomic structure, transforming linear polymer chains into a more thermally stable ladder structure. This step is crucial as it prevents the fibres from melting during the high-temperature carbonisation process.
Alternative Precursors
While PAN is the most commonly used precursor, rayon and petroleum pitch can also be transformed into carbon fibre. Each material results in different fibre characteristics, with pitch-based fibres often used for high-modulus applications such as aerospace engineering. Rayon-derived carbon fibres, on the other hand, offer high thermal stability and are commonly used in applications requiring heat resistance, such as thermal insulation in furnaces.
Applications of Carbon Fibre
Carbon fibre is valued for its high stiffness, strength, chemical resistance, low thermal expansion, and lightweight properties. It is widely used in industries that demand high performance and efficiency, including:
- Aerospace & Defence – Used in aircraft fuselages, wings, and spacecraft components.
- Automotive – High-performance and luxury cars use carbon fibre to reduce weight and improve speed.
- Sports Equipment – Found in bicycles, tennis rackets, golf clubs, and racing boats.
- Medical Field – Used in prosthetics and X-ray-transparent equipment.
- Musical Instruments – Enhances acoustic properties while reducing weight.
Challenges in Carbon Fibre Manufacturing
Despite its advantages, carbon fibre production is energy-intensive and expensive. Some key challenges include:
- Cost of production – The complex manufacturing process drives up costs.
- Surface treatment precision – Must be carefully controlled to prevent defects.
- Quality control – Requires strict monitoring to ensure consistency.
- Electrical conductivity – Can cause issues like electrical arcing in sensitive environments.
- Health and safety risks – Fine fibres can cause skin irritation and respiratory issues.
Carbon Fibre vs Steel: Which is Stronger?
A common question is whether carbon fibre is stronger than steel. While carbon fibre has a higher strength-to-weight ratio, steel remains superior in compressive strength. However, for applications where weight is a critical factor—such as aircraft, cars, and bicycles—carbon fibre is the preferred choice due to its significantly lower weight and comparable tensile strength.
The Future of Carbon Fibre
Carbon fibre’s high cost has historically limited its use to specialised industries. However, advancements in manufacturing techniques—such as forged composite technology and 3D-printed moulds—are making it more accessible. These innovations could lead to increased use in mass-market vehicles and other consumer goods, bringing its benefits to a broader audience.
As sustainability becomes a focus, researchers are also exploring recyclable carbon fibre to reduce environmental impact. New techniques aim to recover and reuse fibres from old products, making the material more eco-friendly.
Final Thoughts
Carbon fibre is a material that blends strength, durability, and lightness in a way that traditional materials like steel and aluminium cannot match. While challenges remain in cost and recyclability, ongoing research and technological improvements are paving the way for wider adoption across industries. As manufacturing costs decrease, we can expect to see carbon fibre in more everyday products, from cars to consumer electronics and beyond.
Would you like to see more details on carbon fibre composites or specific manufacturing techniques? Let me know!
TALK TO THE EXPERTS
Established in 1985, we have built a strong reputation for manufacturing excellent products within tight timescales and to extremely high tolerances. In order to achieve this, we use state of the art equipment and traditional, time honoured processes and skills.
Call us on:
01455 890 571
Email us at:
sales@pentapatterns.co.uk