Carbon fiber tubes have a variety of applications across industries. The hollow length of carbon composite material is one of the strongest materials in spite of being light in weight. They have a particular advantage of strength-to-weight ratio. There are several techniques used to manufacture carbon fiber tubes, each with its own advantages and limitations. Many times the manufacturing process determines the quality of the tubes and its industrial purpose.

No matter how carbon fiber products were manufactured, their characteristic strength, durability, and lightweight properties make it a popular choice for a wide range of industries. Commonly used in sporting goods like telescopic poles, bicycles, golf clubs, tennis rackets, and fishing rods it is corrosion resistant, has high tensile strength and can improve performance by reducing fatigue.

Here are four common techniques used by carbon fiber manufacturers:

• Pultrusion

Pultrusion is a continuous manufacturing process used to produce carbon fiber tubes with a constant cross-section. In this method, carbon fiber rovings (bundles of carbon filaments) are saturated with resin and pulled through a heated die. The die provides the desired tube shape and also cures the resin. As the carbon fiber composite passes through the die, it is pulled by a continuous pulling mechanism. The resulting tube has a uniform cross-section and excellent strength properties. Pultruded carbon fiber tubes are often used in structural applications.

• Roll-Wrapping

Roll-wrapping is a technique where carbon fiber prepreg sheets (carbon fiber fabric pre-impregnated with resin) are wrapped around a mandrel in a helical pattern. The prepreg sheets are cut into strips and applied layer by layer, with each layer slightly overlapping the previous one. The mandrel can be rotated or moved linearly during the wrapping process to achieve the desired tube shape. Once the wrapping is complete, the tube is cured in an oven to harden the resin. Roll-wrapping offers flexibility in fiber orientation and is suitable for small-scale production. The carbon fiber prepreg tubes are available in round and square structures.

• Filament Winding

Filament winding is a popular method for manufacturing carbon fiber tubes. In this technique, carbon fiber filaments are wound around a rotating mandrel in a precise pattern. The filaments are impregnated with epoxy resin during the winding process. The mandrel can be tapered or straight depending on the desired tube shape. After winding, the tube is cured in an oven to harden the resin, and then the mandrel is removed. Filament winding allows for precise control over fiber orientation and offers a high strength-to-weight ratio.

• Resin Infusion

Resin infusion, also known as vacuum infusion, is a method where dry carbon fiber fabrics or preforms are placed in a mold and resin is infused into the fabric under vacuum pressure. The dry carbon fiber fabric is first laid up in the mold, and a vacuum bag is then applied to create a seal. Resin is introduced into the mold under vacuum, allowing it to flow and impregnate the carbon fibers. The resin-infused part is then cured, either at room temperature or in an oven. Resin infusion is a versatile method that can produce complex shapes with controlled resin content and is suitable for large-scale production.

These are just a few examples of the techniques used to manufacture carbon fiber tubes. Each method has its own advantages and may be selected based on factors such as desired tube properties, production volume, complexity of the shape, and cost considerations.

To make the right choice, consider these factors:

Customization: Of the different manufacturing processes choose one that offers flexibility in terms of size, shape, and layup configuration. Manufacturers can easily modify the angle, thickness, and number of carbon fiber layers during the roll-wrapping process, allowing for customized designs tailored to specific requirements in comparison to other products methods.

Consistent mechanical properties: Uniform and predictable mechanical properties throughout the structure. The fiber orientation can be carefully controlled during the manufacturing process, resulting in consistent stiffness and strength characteristics along the length of the tube.

Size and length: Check out which manufacturing process is better suited for producing smaller diameter tubes and structures of shorter lengths. It may be challenging or impractical to manufacture very large or long roll-wrapped tubes due to limitations in the wrapping equipment and process.

Labor-intensive: The method involves manually wrapping carbon fiber prepreg sheets onto a mandrel, which can be a labor-intensive process. It requires skilled technicians to ensure precise fiber alignment and proper consolidation of the layers. As a result, production rates may be slower compared to automated manufacturing techniques.

Complexity in design: Complex designs with intricate shapes, varying diameters, or multiple attachment points can be challenging to achieve with roll-wrapping. The process is more suitable for producing straight or slightly curved tubes. Creating highly contoured or irregularly shaped structures may require additional manufacturing steps or alternative methods.

Choose carbon fiber tubes according to your needs with NitPro Composites. Customize your requirements with different manufacturing processes.

Source by- https://medium.com/@nitprocomposites/4-different-techniques-to-manufacturer-carbon-fiber-tubes-f1068ddcb636