OUR CARBON FIBER
At Highwaygame Industries, we are dedicated to using only 100% genuine carbon fiber, ensuring the highest quality in every composite product we create.
Our manufacturing process employs three advanced techniques: vacuum infusion, autoclave prepreg, and out-of-autoclave (OOA) prepreg. This meticulous approach ensures superior strength and durability while maintaining a lightweight and visually appealing profile.
Each of our carbon fiber parts is proudly handcrafted in the USA, reflecting our commitment to exceptional craftsmanship. We pay close attention to detail at every stage of production, from initial design to final finish, ensuring that our products consistently meet the highest standards of quality.
VACUUM INFUSION
Vacuum infusion carbon fiber is a composite manufacturing technique that involves infusing resin into dry carbon fiber fabric under vacuum pressure. This method is favored for its ability to produce high-quality, lightweight, and strong components, making it widely used in industries like aerospace, automotive, marine, and sporting goods.
The vacuum infusion process begins with mold preparation, where dry carbon fiber fabrics are laid into a mold shaped according to the desired final product. The mold can be constructed from various materials, such as fiberglass or aluminum, depending on the requirements of the project.
Next, vacuum bagging is performed by placing a vacuum bag over the mold and sealing it tightly. This step creates a controlled environment by effectively removing air and moisture from the setup, which is essential for achieving optimal results.
The next phase involves creating a vacuum. A vacuum pump is used to establish a vacuum inside the bag, which is crucial for eliminating air. This step reduces the risk of bubbles and voids forming in the composite material, ensuring a stronger final product.
Once the vacuum is established, the process moves to resin infusion. Resin is introduced through inlet ports, and the vacuum pressure draws it into the dry carbon fiber fabric, ensuring thorough saturation and a strong bond.
Finally, the component undergoes curing. After the resin has fully infused, the part is allowed to cure, which can occur at room temperature or with added heat, depending on the specific resin system used. This curing phase solidifies the composite, resulting in a high-quality, lightweight component ready for use.
AUTOCLAVE PREPREG
Autoclave prepreg carbon fiber is a high-performance composite manufacturing technique that utilizes pre-impregnated carbon fiber fabric cured under heat and pressure in an autoclave.
The process begins with prepreg fabric, which consists of carbon fiber that has been pre-impregnated with a resin system. This means the resin is applied to the fibers in a controlled manner, ensuring a consistent resin-to-fiber ratio essential for the performance of the final product.
Once the prepreg material is ready, it is laid into a mold designed for the intended part. The mold can be made from various materials, such as aluminum or composite materials, depending on the specific application. After the prepreg is positioned in the mold, it is sealed in a vacuum bag to remove any air, and the entire assembly is placed inside an autoclave, which functions as a high-pressure oven.
During the curing process, the autoclave applies both heat and pressure to the assembly. This critical step enhances the strength and durability of the composite material by allowing the resin to cure properly, resulting in a solid, high-quality finish. Once cured, the assembly is allowed to cool slowly, helping to prevent thermal shock and maintain the integrity of the material.
The benefits of autoclave prepreg carbon fiber are significant. This technique produces composites that are extremely strong and lightweight, making them ideal for demanding applications in industries such as aerospace and motorsports. The combination of heat and pressure effectively eliminates air bubbles and voids, resulting in denser and more reliable composites. Additionally, the pre-preg method allows for precise control over the resin-to-fiber ratio, ensuring consistent performance across parts. Moreover, autoclave prepreg carbon fiber can be molded into complex shapes, offering design flexibility, and the curing process often yields a smooth, high-quality surface finish that enhances the final product's appearance. Overall, this technique represents a premium choice for producing advanced composite materials.
Step-by-Step Process for Making Autoclave Pre-Preg Parts
prep and clean the prototype part
we first created a 1 time use temporary mold to produce a master plug
Master plug made from mold-making pre-preg carbon fiber. This robust master plug enables us to efficiently scale up production to meet high demand by streamlining the creation of multiple molds.
This high-quality mold is designed to produce hundreds of parts, ensuring durability and consistent performance throughout its lifecycle.
The prepreg layup process involves several key steps to ensure a high-quality composite structure. Here’s a refined overview:
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Mold Preparation: Clean the mold thoroughly and apply a suitable release agent to prevent sticking during demolding.
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Cutting Prepreg: Cut the prepreg carbon fiber sheets to the required dimensions, accounting for overlaps and any specific design requirements.
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Layering: Carefully place the prepreg sheets onto the mold, ensuring the fibers are oriented according to the strength requirements of the final part. Pay attention to the alignment of overlapping layers for consistency.
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Vacuum Bagging: Once all layers are laid up, cover the assembly with a vacuum bag. Seal the edges to create an airtight environment, which helps eliminate air pockets and compress the layers.
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We then
Following our prepreg carbon fiber cure cycle in the autoclave, we are left with a fully cured, raw carbon fiber part. This component is now solid and dry, ready for inspection and any necessary finishing processes.
We offer four different levels of finish: raw finish (no clear coat), basic budget clear coat finish, satin finish, and show car ready finish.
For more details, visit our CARBON FIBER FINISH page.
raw finish on the left and basic budget clear coat finish
OUT-OF-AUTOCLAVE (OOA)
Out-of-autoclave (OOA) curing refers to composite manufacturing processes that do not require an autoclave for curing prepreg materials. Instead, OOA methods utilize alternative techniques, such as vacuum bagging or resin infusion, to achieve effective curing at lower pressures and temperatures.
This approach is often more cost-effective, as it requires less expensive equipment, thus reducing overall production costs. Additionally, OOA methods offer greater flexibility in part size and complexity, making it easier to manufacture larger components or those with intricate geometries.
While OOA processes may not reach the high temperatures of autoclave curing, advancements in resin technology enable effective curing at lower temperatures, enhancing energy efficiency. Proper vacuum bagging and resin management can still yield high-quality composites with minimal voids and defects, although mechanical properties may vary compared to autoclave-cured parts. As a result, out-of-autoclave techniques are increasingly popular in industries like aerospace, automotive, and marine, where lightweight and high-strength materials are essential.
Overall, OOA curing provides a viable alternative to traditional methods, balancing cost, flexibility, and quality.