What is Forged Carbon Fiber?
Forged Carbon Fiber is a recyclable and environmentally friendly epoxy sheet molding compound prepared by infiltrating short-cut carbon fiber with epoxy resin. Forged composite is a type of carbon fiber SMC material composed of small pieces of carbon fiber composite material that are pressed into shape as the resin cures. This is in contrast to most carbon fiber composites, which are made of larger continuous layers that are ‘laid up’ one at a time. Forged composite allows for a higher range of shapes to be formed with precision, relative to traditional carbon fiber.Forged Composite forgoes the weave and instead uses a random arrangement of loose fibers mixed with resin and forms them in a heated press at high pressure. The resulting composite is strong in all directions without the additional cost and complexity of adding multiple layers of material, as must be done with woven carbon fiber ,It is essentially an upgrade on existing carbon fiber technology ,This new way of producing carbon fiber is lighter and stronger than its predecessor, carbon fiber. Forged carbon fiber is not a specific material or a single process, but rather a comprehensive technology that binds the materials and fuses them together, allowing for the creation of a composite carbon fiber part. This process is what gives forged carbon fiber such a unique look and why it has become so popular with the automotive community.
Physical Properties of Forged Carbon Fiber from tCH composites
| N | Item | Performance | Test Method |
| 1 | Density（g/cm³） | ~ 1.5 | GB/T 1033-2008 |
| 2 | Tensile strength（MPa） | ≥150 | GB/T 1447-2005 |
| 4 | Tensile modulus（GPa） | ≥30 | GB/T 1447-2005 |
| 5 | Flexural strength（MPa） | ≥300 | GB/T 1449-2005 |
| 6 | Flexural modulus（GPa） | ≥28 | GB/T 1449-2005 |
| 7 | Impact strength（KJ/㎡） | ≥120 | GB/T 1043.1-2008 |
What makes this Different from Regular Carbon Fiber?
Traditional carbon fiber is made usable by laying up method in a sheet form and infusing it with resin. On the contrary forged carbon, is a unique technology which involves using a paste of fibers mixed with a resin to be compressed out into several unique collage type designs.
Forged Composite starts off as a sheet of uncured plastic, and is mixed with short randomly placed carbon fiber strands. Unlike traditional carbon fiber sheets, this material does not require careful cutting and precise laying into molds. Once the right mass has been cut and placed into a hot press mold, it is compressed under extreme pressure and heat. You have an object that is as light or lighter and stiffer as a traditional carbon fiber, but with a new unique and one of kind design.
Product features
Our forged Carbon Fiber has rapid molding characteristics, 140 ~ 150 ℃ conditions 5 ~ 10min can be molded composite parts; glass transition temperature 120 ~ 130 ℃; prepared epoxy flake molding plastic composite mechanical properties, the parts can be recycled; No VOC emissions.
| N | Item | Performance | Test Method |
| 1 | Appearance | PE film on both sides, black | / |
| 2 | Proportion of carbon fiber（%，R/C） | 42 ~ 47 | / |
| 3 | Time of resin gelation（sec@120±1℃） | 360 ~ 420 | Hot plate method |
| 4 | Time of resin gelation（sec@150±1℃） | 60 ~ 80 | Hot plate method |
| 5 | Temperature of glass transition（150℃×5min） | 120 ~ 130 | DSC GB/T 19466-2004 |
Forged Composite starts off as a sheet of uncured plastic, and is mixed with short randomly placed carbon fiber strands. Unlike traditional carbon fiber sheets, this material does not require careful cutting and precise laying into molds. Once the right mass has been cut and placed into a hot press mold, it is squeezed under high pressure, heated, and voila! — You have an object that is as light and stiff as a traditionally created carbon fiber object; only this one is produced in minutes instead of hours
Applications
One of the industries that have adopted forged carbon fiber is the automotive industry. Car manufacturers have used forged carbon fiber to create various components, including body panels, steering wheels, and interior trims. Forged carbon fiber components are not only lightweight, but they also have high stiffness, which enhances the car’s handling and overall performance.
Apart from the automotive industry, forged carbon fiber has also found its way into the world of luxury goods. Manufacturers of high-end watches and jewelry have embraced this material due to its unique appearance and properties. Forged carbon fiber watches have become increasingly popular due to their durability, scratch resistance, and lightweight. The material also allows for intricate designs that are not possible with traditional materials.
Another industry that has benefited from the use of forged carbon fiber is the sports equipment industry. Forged carbon fiber is used to manufacture various sports equipment, including tennis rackets, golf clubs, and bicycles. The material’s lightweight properties help athletes perform better, while its strength and durability allow for long-lasting equipment.
Conclusion
forged carbon fiber is a unique material that has revolutionized various industries, including automotive, luxury goods, and sports equipment. Its unique properties, including high strength-to-weight ratio, stiffness, and eco-friendliness, have made it a popular choice for manufacturers looking to create high-performance and durable products. With continued research and development, forged carbon fiber is likely to find its way into even more applications, further enhancing its reputation as a lightweight and durable solution.
