Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Carbon fiber die casting isn’t a standard process in the way aluminum die casting is, as carbon fiber components are typically made using composite molding techniques rather than traditional die casting, which involves injecting molten metal into a mold. The search results you provided and general manufacturing knowledge suggest that what’s often referred to as “carbon fiber die casting” is more accurately described as molding or forming processes like resin transfer molding (RTM), vacuum-assisted RTM (VaRTM), or prepreg compression molding (PCM). These processes shape carbon fiber composites using molds, sometimes resembling die casting principles. 

1.Here’s how it generally works:

a.Mold Design and Preparation:A mold (often made of steel, aluminum, or composite materials like fiberglass) is designed to match the desired part’s shape. For carbon fiber, molds must withstand resin curing conditions (heat and pressure).Release agents are applied to the mold surface to ensure easy removal of the cured part.

b.Carbon Fiber Placement:Carbon fiber fabric (woven sheets or preforms) or prepreg (carbon fiber pre-impregnated with resin) is laid into the mold. The fibers are carefully oriented to optimize strength and performance based on the part’s design.Unlike aluminum die casting, no molten material is injected; the carbon fiber is placed manually or via automated processes.

c.Resin Application:In Resin Transfer Molding (RTM), dry carbon fiber preforms are placed in a sealed mold, and liquid resin (typically epoxy) is injected under pressure to impregnate the fibers. The mold is then heated to cure the resin .In Vacuum-Assisted RTM (VaRTM), a vacuum is used to pull resin through the fibers, suitable for larger parts.For Prepreg Compression Molding (PCM), prepreg sheets (already impregnated with resin) are stacked in the mold, then compressed and heat-cured.

d.Curing:The mold, with carbon fiber and resin, is placed in an oven, autoclave, or heated press to cure the resin at specific temperatures (often 120–200°C) and pressures. This bonds the resin to the carbon fibers, forming a rigid, lightweight structure.Autoclave or vacuum bagging can enhance quality by applying uniform pressure, reducing voids.

e.Demolding and Finishing:After curing, the mold is opened, and the part is removed. Release agents ensure clean demolding.

The part may be trimmed, sanded, or machined to achieve precise dimensions and surface finish. Quality checks (e.g., dimensional measurements, strength tests) ensure the part meets specifications.

f.Alternative Processes:Some methods, like filament winding or pultrusion, are used for specific shapes (e.g., pipes or rods) but aren’t true die casting. These involve winding or pulling carbon fiber through resin baths and curing in molds.3D printing with carbon fiber-reinforced resins (e.g., chopped fibers in nylon) or printed molds for carbon fiber layup is an emerging technique for low-volume production.

2.Key Differences from Aluminum Die Casting:

a.Material: Aluminum die casting uses molten metal; carbon fiber processes use solid fibers and liquid resin.

b.Process: Aluminum die casting injects molten metal under high pressure; carbon fiber molding typically involves manual or low-pressure resin infusion and curing.

c.Mold Materials: Aluminum die casting requires hardened steel molds due to high temperatures and pressures; carbon fiber molds can be aluminum, fiberglass, or even 3D-printed polymers for low-volume runs.

4.Applications: Carbon fiber molding is used for lightweight, high-strength parts in aerospace, automotive, and sports equipment (e.g., fender air ducts, golf shafts).

5.Challenges:Carbon fiber molding is slower and more labor-intensive than aluminum die casting.

Molds for carbon fiber are less durable for high-volume production compared to steel dies.