When composites are cheaper upfront

Every project needs its own cost analysis, taking into account its specific requirements. That said, composites can sometimes be more affordable than metals when manufacturing certain parts.

In many cases, the cost of a component is driven more by design complexity and manufacturing processes than by raw material price. This is where composites can offer a clear advantage.

Why? Because composites are made differently. Their manufacturing processes allow for simpler designs in many cases, reducing the need for additional steps. For example, a carbon fiber part can end up being more cost-effective than its metal counterpart if the latter requires extra labor such as welding, machining, or other post-processing.

One of the key advantages of composites is part consolidation—the ability to integrate multiple components into a single part, reducing assembly time, fasteners, and potential points of failure.

It’s also worth noting that not all composites are created equal. Carbon fiber with epoxy resin is usually on the higher end in terms of cost, but there are many other fiber types and material combinations that offer lower costs while delivering increasingly competitive mechanical performance.

Other ways composites become cost-effective

Even when a composite part has a higher upfront cost than a metal alternative, it can still be the more cost-effective choice overall. Lightweight components, for instance, can reduce the need for additional structural reinforcements. In other cases, composites eliminate the need for corrosion protection, which can significantly increase total system costs.

Big FRP pipes. HOBAS CC BY-SA 3.0

A good example is fiber reinforced plastic (FRP) pipes. These pipes are strong and lightweight, which reduces transportation and installation costs. They are also highly resistant to corrosion and abrasion, which is why they are widely used for transporting corrosive liquids, aggressive chemicals, fluids, and gases.

FRP pipes typically use reinforcement fibers such as glass, ensuring long-lasting performance that often exceeds 50 years. They are suitable for underground applications, and their low coefficient of thermal expansion makes them a very good option when exposed to temperature fluctuations above ground.

There are also performance-related advantages. While every composite is different, they generally offer better fatigue resistance than most conventional metals. This can translate into fewer inspections, less maintenance downtime, higher availability, and a reduced need for spare parts.

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Cost-effectiveness over the full product lifecycle

In many cases, the real value of composites becomes clear over the product’s lifecycle. A common mistake is to evaluate materials based only on upfront cost, without considering operational and maintenance savings over time. This is where lifecycle analysis comes into play, as it looks beyond the initial purchase cost.

Closeup of a Boeing 787

As we highlighted in our previous article on why carbon fiber is more expensive than other materials, transportation is one of the clearest examples.

In the latest generation of commercial aircraft, such as the Boeing 787 and the Airbus A350, the primary structure is made from carbon fiber reinforced plastic (CFRP), making them lighter and more fuel-efficient. These aircraft consume approximately 20% to 25% less fuel than previous equivalent models, although this also includes improvements from new engines and other innovations.

While composites can increase manufacturing costs, in aviation they can enable components that are 20% to 50% lighter than their metal equivalents. This leads to a significant reduction in fuel consumption, as heavier aircraft require more lift, which in turn generates more drag. This is especially relevant for long-haul flights, where large amounts of fuel—and therefore weight—must be carried.

When you look at the full lifecycle, composites often prove to be highly cost-effective—not just economically, but also from a sustainability standpoint. Their lower weight reduces fuel consumption, making them more efficient to operate and lowering CO₂ emissions. In addition, their superior fatigue resistance is one of the reasons why the use of composites in aviation continues to grow.

Continuous innovation is pushing composites further

Metal manufacturing is a highly mature field, shaped by decades of widespread use. Composites, on the other hand, are relatively new in industrial terms and continue to grow rapidly.

This means a lot of ongoing innovation. Research and development in composites is intense, and new breakthroughs are happening all the time. Each innovation unlocks solutions that weren’t possible just a few years ago. New materials, new combinations, new processes—you name it. All of this is expanding the range of applications where composites are not just viable, but the most cost-effective option available.

And that list keeps growing.

The post When are composites cost-effective? appeared first on Managing Composites.

Composite manufacturing methods range from highly manual processes to fully automated

Steps for Manufacturing in Composites

In any composite manufacturing process (fiber + resin), there are four essential steps, not always in this particular order which may be reduced to three depending on the type of material used.

• Impregnation: The resin, in liquid state, comes into contact with the fiber reinforcement and impregnates it. When using prepreg materials, this step is not required, as the fibers are already pre-impregnated.
• Lay-up: Placement of the fiber reinforcement onto the mold that defines the shape of the final part. Multiple layers can be stacked over the entire part or locally in specific areas to increase thickness and mechanical strength.
• Consolidation: Compaction of the different layers and removal of voids to prevent structural weaknesses in the final component.
• Curing: Activation of the chemical polymerization process, during which the resin transitions from a liquid to a solid state.

Once these fundamental steps are understood, the different manufacturing techniques used to produce composite parts can be examined.

Open Molding Processes

Wet Lay-Up (Hand Lay-Up)

A release agent or gel is first applied to the mold to prevent the part from sticking. Reinforcement mats or fabrics are then cut to size and placed on the mold surface, after which the resin is poured and spread evenly.

The simplest composite manufacturing method, accessible to virtually anyone, where fibers are manually impregnated with resin using basic tools.

Layers of reinforcement and resin are built up sequentially, using rollers to remove trapped air and excess resin. After curing at room temperature or under elevated temperature, the composite part is removed from the mold and prepared for further finishing operations.

Pros:

• Low tooling and equipment cost
• High process flexibility
• Suitable for large or custom parts

Cons:

• Strong dependence on operator skill
• Limited control over fiber-to-resin ratio
• Lower repeatability and longer cycle times

Spray-Up

Spray-up is a widely used technique for glass fiber parts that accelerates traditional wet lay-up by spraying chopped reinforcement fibers and liquid resin directly onto the mold surface. Layers are built up rapidly until the desired thickness is reached, and the process is often combined with gel coat application.

The process uses a spray gun equipped with a fiber chopper that cuts continuous glass fiber rovings into short lengths, typically between 25 and 75 mm, which are mixed with resin during spraying. This results in randomly oriented fibers that must be compacted by rolling, similar to hand lay-up.

Pros:

• Faster than traditional hand lay-up
• Widely used and effective for fiberglass parts
• Simple, well-understood process with easy operator training

Cons:

• Random fiber orientation limits mechanical performance
• High resin content and lower laminate quality compared to closed-mold processes
• Lower surface finish and dimensional control

Prepeg

Prepreg materials consist of fiber reinforcements that are pre-impregnated with a precisely controlled amount of resin during manufacturing. The resin is typically partially cured (B-stage), allowing the material to remain tacky and easy to handle until final curing.

Because impregnation is already completed, the manufacturing process focuses on lay-up, consolidation, and curing. Traditionally, prepregs are cured under heat and pressure in an autoclave, which enables excellent consolidation and very high laminate quality. However, in recent years, Out of Autoclave (OoA) prepregs have been developed to reduce processing cost and complexity.

Pre-impregnated fibers (prepregs) are a very common choice for high-performance applications.

Prepregs offer outstanding control over fiber-to-resin ratio and laminate consistency, making them a preferred choice for high-performance applications where repeatability, structural integrity, and surface quality are critical.

Pros:

• High laminate quality and repeatability
• Superior mechanical performance
• Excellent control of fiber-to-resin ratio

Cons:

• Higher material cost compared to dry fabrics
• Requires controlled storage and handling (typically refrigerated)
• Autoclave equipment often required, depending on prepreg type

Vacuum Infusion

This process, also known as Resin Infusion, is an open-mold method widely used in boat building and wind energy applications, as it enables the manufacture of very large parts with relatively precise fiber-to-resin ratios.

All reinforcement fabrics are first cut, positioned, and laid into the mold in a dry state, then sealed under a vacuum bag. Resin inlet lines are arranged and connected prior to sealing, creating a controlled resin delivery network. Once vacuum is applied, the pressure differential draws liquid resin through the inlet lines and distributes it across the dry reinforcement. Resin flow is guided by flow-assisting elements such as mesh layers, channels, or grooved core materials to ensure uniform impregnation.

Pros:

• Suitable for large, complex parts (e.g., boat hulls, wind turbine blades)
• Good surface finish on the mold side
• Lower resin content and higher fiber volume fraction than other open-mold methods

Cons:

• More complex setup and planning than basic open-mold processes
• Requires careful control of materials, flow media, and resin viscosity
• Less suitable for very high-volume production compared to automated closed-mold methods

Resin infusion is often used to manufacture very large composite parts, such as boat hulls, where controlled resin flow and material consolidation are critical.

Closed Mold Processes

Resin Transfer Molding (RTM)

In RTM, mixed resin and catalyst are injected into a closed mold containing a dry fiber preform. This process produces components with good surface finish on both sides and allows precise control over fiber architecture, orientation, and laminate thickness, as defined by the mold cavity.

Schematic of a Resin Transfer Molding (RTM) process.

RTM supports a wide range of resin systems—including polyester, vinyl ester, epoxy, phenolic, and MMA—as well as reinforcements such as glass, carbon, aramid, or hybrid fibers. The process can be automated to increase production rates while reducing scrap, making it a common choice for industrial applications.

Pros:

• Good surface finish on both sides
• Tight dimensional tolerances and uniform thickness
• Ability to mold complex structural and hollow parts

Cons:

• Higher tooling cost than open-mold processes
• More complex process control
• Not ideal for very low or very high production volumes

Resin Transfer Molding Variants

HPRTM (High Pressure RTM) is a variant of the RTM process in which resin is injected at high pressure, enabling the production of parts with high structural quality, excellent repeatability, and very short production cycles.

LRTM (Light RTM) is another variant that uses very low resin injection pressures, significantly reducing tooling cost and complexity.

Compression Molding

Compression molding is a manufacturing process used with materials such as sheet molding compound (SMC), bulk molding compound (BMC), and thick molding compound (TMC). It employs heated metal molds installed in hydraulic presses and can be highly automated. The process offers significant design flexibility, allowing features such as inserts, ribs, and bosses, while achieving good surface finishes that reduce secondary finishing operations and labor costs.

During production, a measured charge of material is placed into a heated mold, which is then closed and compressed until curing is complete, typically within one to five minutes. The finished part is then removed. Tooling consists of durable heated metal molds, usually made of steel, which are highly durable but also relatively expensive.

Pros:

• Short cycle times and high productivity
• Low labor cost
• Good dimensional control

Cons:

• High tooling cost
• Limited design flexibility after tooling
• Part size and thickness limitations

Prepreg Compresion Molding

Prepreg Compression Molding (PCM) combines the material quality of prepregs with the productivity of compression molding. In this process, stacks of prepreg material are placed into a heated matched-metal mold, which is then closed under pressure to consolidate and cure the laminate in a single step.

The use of closed molds enables good surface finish on both sides, tight dimensional control, and short cycle times, making PCM well suited for medium- to high-volume production. Compared to autoclave-cured prepregs, PCM significantly reduces processing time while maintaining a high level of structural performance.

PCM is widely used in automotive and industrial applications where repeatability, productivity, and mechanical properties must be balanced with cost.

Pros:

• Short cycle times
• Good surface finish and dimensional accuracy
• Suitable for medium- to high-volume production

Cons:

• High tooling cost
• Limited flexibility once tooling is defined

Automated & Continous Systems

Pultrusion

Pultrusion is a continuous manufacturing process used to produce composite parts with a constant cross-section, such as beams, profiles, and structural elements.

In this process, continuous fibers are pulled through a resin bath or resin injection chamber to impregnate them, then guided through a heated die that defines the final shape and cures the resin. Once cured, the profile is continuously pulled and cut to length.

Pultrusion delivers excellent fiber alignment and high fiber volume content, resulting in strong, lightweight components produced with high efficiency and minimal material waste. It is commonly used for structural profiles in construction, infrastructure, and industrial applications.

Pros:

• Continuous, highly efficient production
• Excellent fiber alignment and mechanical performance
• Low labor cost and minimal waste 

Cons:

• Limited to constant cross-section parts
• High initial tooling cost
• Low geometric flexibility

Filament Winding

In this method, continuous fibers (such as glass, carbon, or aramid), impregnated with resin, are wound under tension onto a rotating mandrel in a controlled geometric pattern. Fiber orientation is selected based on load requirements, enabling the production of strong, lightweight hollow structures such as pipes, tanks, and pressure vessels.

Once the required thickness is achieved, the laminate is cured on the mandrel using heat, and the finished part is either removed or left with a permanent liner. The process is highly automated, offering excellent precision, repeatability, and high fiber volume content, making it ideal for structural and pressure-related applications.

Pros:

• Excellent mechanical performance for cylindrical and axisymmetric parts
• Highly automated and repeatable
• Efficient material usage compared to alternative processes

Cons:

• Limited geometric flexibility
• Mandrel removal can be complex
• Surface finish often requires secondary operations

Automated Fiber Placement (AFP)

Automated Fiber Placement (AFP) is used to produce lightweight, high-strength structures, particularly for aerospace and high-performance industrial applications. It uses pre-impregnated fiber tows, typically carbon/epoxy, which are automatically placed onto complex molds or mandrels with high accuracy.

The use of robotic tools enables high precision and repeatability.

During the process, multiple narrow tows are heated, compacted, and laid down by a robotic head in predefined orientations such as 0°, ±45°, and 90°, building the laminate layer by layer. AFP offers high precision, excellent material efficiency, and the ability to manufacture complex geometries, making it suitable for structural components where performance and repeatability are critical.

Pros:

• High precision and repeatability
• High level of automation
• Ability to manufacture complex geometries

Cons:

• Very high equipment cost
• High programming and setup complexity
• Expensive raw materials

Composites manufacturing methods comparison

TL;DR

Composite parts are made by combining fibers and resin through different manufacturing processes, all of which follow the same basic steps: impregnation, lay-up, consolidation, and curing (with impregnation omitted for prepregs). Each process offers a different balance between cost, complexity, quality, automation, and production volume.

• Open-mold processes (Wet Lay-Up, Spray-Up, Vacuum Infusion) are low-cost and flexible but have lower repeatability and quality control.
• Closed-mold processes (RTM, LRTM, HPRTM, Compression Molding) provide better surface finish, dimensional accuracy, and structural performance at higher tooling cost.
• Automated processes (Filament Winding, AFP) deliver the highest performance and repeatability but require significant investment and are best suited for specific geometries or high-performance applications.

There is no single “best” process—the optimal choice depends on part geometry, mechanical requirements, production volume, cost targets, and level of automation required.

The post Manufacturing Methods in Composites appeared first on Managing Composites.

Computer Vision Assisted Quality Control tools automatically generate Fiber-orientation maps, showing real ply angles across the carbon-fiber laminate and highlighting deviations that could affect structural performance and visual quality.

Inspections Before Manufacturing

Quality starts way before anyone touches a mold. Fibers and resins go through chemical and mechanical checks to make sure every batch behaves the way it should. Prepregs get their own VIP treatment: areal weight, resin distribution, tack, and general condition are inspected to confirm they’ll process smoothly and won’t surprise anyone halfway through a layup.

Only after materials pass documentation reviews and supplier audits — full traceability, stable processes, no mysteries — are they allowed anywhere near production. This is how you avoid building defects into the part before the part even exists.

Inspections During Manufacturing

Once manufacturing kicks off, the mission is simple: every ply exactly where it’s supposed to be, every process parameter exactly as specified. Cure temperatures, ramp rates, pressure, dwell times — composites don’t forgive improvisation.

Fiber orientation, ply sequence, handling… everything gets monitored to avoid wrinkles, gaps, overlaps, and other uninvited guests. Vacuum integrity and consolidation are checked constantly to keep porosity and trapped air out of the picture. Real-time inspection is your best friend here — catch issues early, long before they become laminate-level drama.

Computer-vision tools automatically detect upward or downward trends in key variables—often long before they go out of tolerance—allowing corrective adjustments to be applied in time.

This is where automated computer vision really shines. Deviations humans would never catch? Detected instantly. That’s why at Managing Composites we built ESEN·EYE: it spots early-stage deviations, and keeps your process comfortably inside tolerance instead of flirting with disaster.

Inspections After Manufacturing

After demolding, the inspection game isn’t over — it just gets more forensic. Among other Non Destructive Tests (NDT) available, Computer-vision systems like ESEN·EYE capture high-resolution details to spot wrinkles, dry areas, pinholes, FOD or any cosmetic defects that think they can hide.

This image shows the result of an automatic diameter analysis on a machined hole in a carbon-fiber component. The system overlays precise inner and outer diameter measurements, detects deviations from nominal values, and highlights tolerance issues instantly.

Fiber alignment and orientation (the silent heroes of performance and aesthetics) get checked with precision. Inserts, machining features, geometry, symmetry — all the usual suspects — are validated against the exact spec of your production line. And because computer vision doesn’t get tired, moody, or biased, every measurement stays fully objective.

Other Benefits of Computer-Vision-Assisted Quality Control

Scanning 100% of every part means nothing slips through. Automatic quality reports give you a crystal-clear snapshot of each component, plus full traceability and a historical production archive — ideal for audits, troubleshooting, or proving to someone that yes, the part was perfect when it left your shop.

Collecting statistical data from every part and every production run allows manufacturers to keep a full record of each component, build statistical databases, and apply data-analysis tools to continuously improve the manufacturing process

TL;DR

Quality control in composites matters because you’re literally manufacturing the material as you build the part.

Before production: fibers, resins, and prepregs should be checked, so no defect sneaks in disguised as a “raw material issue.”

During production: monitor layup, fiber orientation, vacuum, and cure — with systems like ESEN·EYE catching early-stage deviations your eyes will never see.

After production: high-resolution computer vision verifies surface quality, fiber alignment, geometry, inserts… everything — delivering reliable specs and full traceability.

The post How to Enhance Quality Control in Composites appeared first on Managing Composites.

That’s why we created The Native Lab, a platform dedicated to composites learning, accessible to anyone with a computer, where we share knowledge about our passion: composites.

Top Composites Courses

Managing Composites is an engineering company specialized in high-level developments in sectors such as aerospace, marine, and automotive. In particular, the hypercar and motorsport sectors are where the company has earned the strongest reputation, thanks to the large number of projects in which results have exceeded expectations. You’ve probably seen our work… You just didn’t know it was us.

We design some of the most cutting-edge composite solutions in the world for the most demanding industries, relying on engineers who come from some of the most advanced companies on the planet: Airbus, Mercedes AMG F1 Team, Koenigsegg… All courses at The Native Lab are designed and delivered by our engineers, drawing directly from experience in the world’s most prestigious companies.

For example, our Composite Materials Program is taught by Eneko Angulo (formerly McLaren and Koenigsegg) and Sergio de Juan (formerly Airbus). The Monocoque Design Program is led by Lluc Martí (formerly Koenigsegg), Alejandro Batán (formerly Prodrive and McLaren), and Marc Oliva (formerly Koenigsegg and McLaren). These are just a few examples of the instructors behind The Native Lab’s programs—professionals whose expertise gives our certifications strong recognition within the industry.

Composites hands-on bootcamps. The real deal

Growing demand for practical training led us to launch a series of bootcamps designed to provide hands-on experience working with composites, learning the tips and tricks gained from years of industry experience. We currently offer bootcamps for three manufacturing technologies.

The Prepreg Bootcamp is offered at Level 1 and Level 2, with the latter intended for those who have completed the first course. We also offer an intensive alternative consisting of five consecutive days of pure hands-on immersion in the manufacturing of carbon-fiber prepreg parts.

The second manufacturing method for which we offer bootcamps to gain hands-on experience is the most traditional one: Wet Layup. This 100% practical training covers all the key aspects needed to implement this method successfully.

The third technique is taught in the Resin Infusion Bootcamp, where participants practice resin impregnation under vacuum—from designing infusion layouts to applying releasing agents correctly to ensure a successful manufacturing process.

This fully practical training is the perfect opportunity to learn directly from our instructors—professionals with hands-on composite lamination experience in top-tier environments such as Formula 1 teams and aerospace factories—who share the techniques that ensure success and efficiency when manufacturing high-performance carbon-fiber parts. And it’s not just for industry: our bootcamps can also be tailored AdHoc for Formula Student teams, Moto Student teams, and companies looking to have their people trained by the best.

Composite Talks

In addition to the courses described above and the other training resources available on The Native Lab, the platform offers free access to Composite Talks. These include a series of interviews, webinars, and presentations featuring high-interest topics and leading voices in the composite materials sector..

From the challenges faced in developing Natural Fiber Composites to the aerodynamic design of vehicles, this section brings together some of the industry’s most notable professionals to share their insights with us. The Native Lab is a highly specialized training platform that remains committed to its founding mission: providing anyone in the world with access to high-quality content related to composite materials. No barriers, no drama, just the good stuff.

The post Expert composites courses… but cooler appeared first on Managing Composites.

The use of steel and carbon fiber offers endless possibilities for engineers.

Tensile strength refers to a material’s ability to resist pulling loads without breaking. However, this can be a tricky question to answer, since these two materials are fundamentally different. Their mechanical behavior depends on many factors, and a direct, absolute comparison is not entirely fair. Let’s take a closer look at their characteristics.

Comparison Between Steel and Carbon Fiber

*These are average, representative values for each type of material, as there are special grades of steel and carbon fiber composites that can differ widely.

Summary:
Per unit of weight, carbon fiber composites are far stiffer and stronger than steel. Even the standard carbon fiber grade shows an order of magnitude higher breaking length, which means it can sustain far more load relative to its weight before failing.

Why Is It So Hard to Define Which Material Is Stronger?

First, both belong to very broad families of materials. Steel properties vary considerably depending on the type — whether it’s carbon steel, stainless steel, or high-strength alloy steel.

The same applies to carbon fiber: there are numerous types of fibers and resins, and every combination results in a composite with unique mechanical properties.

Carbon fiber and its composites are anisotropic, meaning they have very high strength along the direction of the fibers but much lower strength transversely. This is especially relevant for unidirectional composites, where the load direction determines the performance. That’s why many woven carbon fabrics include layers oriented at 0° and 90° to balance mechanical behavior and improve overall performance.

So… Is Carbon Fiber Stronger Than Steel?

The short answer: yes — because carbon fiber generally has a much higher specific strength and absolute tensile strength than steel.
But when you analyze it more deeply, there are many variables that influence the outcome, and a simple direct comparison is not truly representative.

When Is It Better to Use Carbon Fiber, and When Is Steel the Right Choice?

As we’ve seen, these materials are so different that one cannot be said to be universally “better” than the other without considering the application.

• Carbon fiber is the better choice when weight reduction is a key factor, thanks to its unmatched strength-to-weight ratio.
• Another reason why steel is often the more convenient choice is its behavior in the event of catastrophic failure, which is more favorable than that of composites for many applications.
• Steel tends to perform better when components must endure compressive loads or high-impact conditions.

Each material comes with its own advantages and drawbacks, so the right choice depends on the application and the specific requirements for each part.

How to Compare Carbon Fiber with Steel in Real Life

Metals and composites are so different that they should not be seen as substitutes for one another. At Managing Composites, we believe that focusing solely on mechanical test data only shows part of the picture. The true potential of these materials lies in the specific design and the intended function of the part. Composites enable designs that metals simply cannot achieve. Therefore, they should not be understood as a replacement, but rather as a distinct material category — one with its own design logic, advantages, and engineering possibilities.

TL;DR

• Carbon fiber outperforms steel in strength-to-weight and stiffness-to-weight ratios.
• Steel remains superior in toughness, ductility, catastrophic failure behavior and thermal stability.
• A direct comparison between carbon fiber and steel is very complex, since these are two very different families of materials, each with variants that have widely diverse characteristics.
• Choosing between them depends entirely on the design, load case, and purpose of the part.

The post Is Carbon Fiber Stronger Than Steel? appeared first on Managing Composites.

Carbon fiber composites offer an unbeatable strength-to-weight ratio, making them the ideal material for high-performance components.

Carbon Fiber Production

As we explained in this article, carbon fiber is produced from organic polymers known as precursors, most commonly polyacrylonitrile (PAN). About 90% of all carbon fiber is made from PAN, while the remaining 10% comes from rayon or petroleum pitch.

Carbon fiber production involves energy-intensive stages and specialized materials.

As shown in the diagram, creating carbon fiber filaments is a complex process that involves polymerizing the precursor, fiber spinning, thermal stabilization, carbonization (and sometimes also graphitization), surface treatment, washing, drying, sizing, and winding. Some of these steps are energy-intensive, and others require costly materials, which gradually drives up the price of carbon fiber.

Limited Use

Carbon fiber is becoming increasingly popular, and more and more products are being made from carbon fiber composites. However, compared to metals, it still represents a niche material, which means it cannot yet benefit from the same economies of scale as its metallic counterparts. Even so, the use of carbon fiber continues to grow every year, so its rising adoption is expected to help bring costs down over time.

One of the sectors that makes intensive use of carbon fiber is aviation, although it produces very specialized products: few units per year and very large parts, making it a highly unique process that is difficult to replicate elsewhere.

The BMW i3 sold more than 200.000 units, developing a true massive industrial production process with carbon fiber

The BMW i3 is one of the best examples of the mass use of carbon fiber. This model, manufactured in Leipzig, was the first mass-produced car to feature a monocoque chassis made from this material. Its production ended in 2022 after nine years and more than 200,000 units manufactured, developing a true mass production industrial process with composite materials.

Craft-Based Manufacturing

Although there are industrial manufacturing processes for high-volume carbon fiber parts, most production remains low-volume and requires highly manual, craft-based techniques. These processes depend on skilled technicians —who are in high demand— since the quality of the final product relies heavily on their expertise.

They also require many hours of labor, as it’s not cost-effective to automate small-scale production. As a result, the labor costs of these products are much higher than those of mass-produced items.

Specialized Equipment

Manufacturing carbon fiber composite parts often requires specific equipment. Autoclaves for curing, storage rooms for prepregs, and other tools and facilities depending on each project can significantly increase overall costs. In contrast, metal manufacturing typically benefits from equipment that is already widely available and often fully or partially amortized.

High-Performance Designs

Carbon fiber is used in some of the most exclusive machines in the world, whose components require hundreds or even thousands of hours of design work. For instance, when a Formula 1 part made of carbon fiber is said to cost a certain amount, the material itself accounts for only a small fraction —most of the cost comes from the engineering hours invested in its development.

Some applications of carbon fiber require the most exclusive variants to achieve the highest possible performance, regardless of cost.

This also applies to many high-end sports equipment components, accessories, and similar products. The top-of-the-line models —which usually feature carbon fiber— have the highest prices, but their cost is not just about the material; it also reflects their extensive R&D investment.

When Carbon Fiber is Cost-Effective

Although carbon fiber parts are generally expensive, there are cases where they can actually become the most economical option. Because components can be built differently than with other materials, carbon fiber enables designs that would be impossible —or much more complex— in metal. In some cases, a part that would require extensive welding and processing in metal can be manufactured in one step with carbon fiber, ultimately making it the more affordable option.

When Carbon Fiber is the Most Profitable Investment

Sometimes, even when carbon fiber isn’t the cheapest option upfront, it turns out to be the most cost-effective in the long run. This is often the case in vehicles, where using carbon fiber helps reduce overall weight —and therefore energy consumption. This improved efficiency means that the initial investment in carbon fiber pays off quickly, making it the most profitable choice.

TL;DR

Carbon fiber isn’t pricey just because it’s high-tech —it’s because making it is hard work. It starts with costly precursors (mostly PAN) and goes through several energy-intensive steps before becoming usable.

Add to that:

• Small-scale, craft-based manufacturing that demands skilled technicians.
• Specialized equipment like autoclaves and cold-storage rooms.
• High R&D investment, especially in top-performance applications like Formula 1 or aerospace.

Although carbon fiber is usually expensive, it can still be the most cost-effective option —either because it lowers operational costs or, in some cases, because it’s actually cheaper to produce.

The post Why is carbon fiber so expensive? appeared first on Managing Composites.

A second use of the term points to carbon fiber fabric — the woven or unidirectional textiles produced from bundles of carbon filaments, before being combined with resin.

Carbon fiber filaments are much thinner than a human hair—around 5 to 7 microns in diameter—yet far stronger, which explains their crucial role in high-performance composites

Finally, carbon fiber filaments may also be referred to as carbon fiber. These are extremely thin strands, typically around 5 to 7 micrometers in diameter, much finer than a human hair. They are composed of long chains of carbon atoms arranged in a highly ordered structure, giving them exceptional tensile strength and stiffness.

Filaments are usually bundled together into tows containing thousands of fibers, which then serve as the basis for producing fabrics and composites.

How is carbon fiber made?

Carbon fiber is produced from organic polymers known as precursors, most commonly polyacrylonitrile (PAN). About 90% of all carbon fibers are made through the PAN process, while the rest originate from rayon or petroleum pitch. Not all carbon fiber is identical and different qualities and grades are achieved depending on the manufacturing method and the gases, liquids, and other materials used.

Carbon fiber production begins with PAN precursor, which undergoes stretching, oxidation, carbonization, and graphitization before surface treatment, sizing, and winding into tows ready for composite manufacturing.

The production of carbon fiber involves several controlled stages:

• Spinning – the precursor is mixed with other ingredients, spun into fibers, washed, and stretched.
• Stabilizing – chemical treatment alters the fibers to make them thermally stable.
• Carbonizing – the stabilized fibers are heated at very high temperatures, forming tightly bonded carbon crystals.
• Surface treatment – oxidation of the fiber surface improves bonding with resins.
• Sizing – a protective coating is applied, and fibers are wound into tows or yarns for further use.

What resins are used for carbon fiber composites?

In the vast majority of cases, when people talk about carbon fiber composites, they are referring to carbon fiber combined with an epoxy resin. Epoxies dominate because they offer excellent mechanical strength, chemical resistance, and fatigue performance, making them the default choice for aerospace, automotive, and high-performance applications.

Epoxy resin is the most common polymer matrix for carbon fiber composites, delivering high strength, durability, and chemical resistance in aerospace, automotive, and advanced engineering.

Other resins can be used, but much less frequently.

Polyester resins are cheaper, though they provide lower performance. For this reason, they are more commonly paired with glass fiber, which is also more economical, rather than with carbon fiber.

Vinyl ester resins sit somewhere in between, offering greater toughness and chemical resistance than polyester but not quite matching epoxy, which explains why the most common combination remains carbon fiber with epoxy resin.

There are also special-purpose resins. Phenolic resins are valued for their fire resistance and low smoke emission, making them suitable for specific applications.

Another example is the resin we used at Managing Composites in the European research project MC4, focused on circularity in composite materials. For this project, we built a kayak in composite materiales which can be reshaped and reused at the end of life of the product thanks to a vitrimer resin developed by CIDETEC. This resin is a thermosetting polymer that behaves like a thermoset at service temperatures but can be healed or partially reprocessed by applying heat and pressure.

Key characteristics of carbon fiber

• High strength-to-weight ratio. Carbon fiber composites can achieve the strength of steel at a fraction of the weight.
• High stiffness. The ordered atomic structure of carbon filaments provides exceptional rigidity.
• Anisotropy. The properties of carbon fiber composites depend strongly on the orientation of the fibers, which allows engineers to tailor stiffness and strength in specific directions.
• Fatigue resistance. Properly designed carbon composites maintain their properties under repeated stress cycles better than many metals.
• Corrosion resistance. Unlike metals, carbon fiber does not rust and shows good resistance to chemical attack, although galvanic corrosion may occur in direct contact with aluminum.
• Thermal properties. Carbon fibers withstand high service temperatures depending on the specific resin matrix.

Common Applications of Carbon Fiber

Carbon fiber has steadily expanded from its origins in aerospace and defense into a wide range of industries. As manufacturing methods improve and costs gradually decrease, it continues to gain prominence in new sectors, where its strength, lightness, and durability unlock performance advantages that traditional materials cannot match. Today, it is found not only in high-tech engineering but also in products that are part of everyday life.

The Airbus A350-1000 is built with over 50% carbon fiber reinforced polymer composites, reducing weight while boosting fuel efficiency and performance.

Some of the most common applications include:

• Aerospace: Aircraft structures, helicopters, turbine parts, aircraft interiors, and space components.
• Automotive: High-performance cars, electric vehicles, body panels, motorbike parts, and structural reinforcement.
• Sporting goods: Bicycle frames, tennis rackets, surfboards, skis, and helmets.
• Marine: High-performance boat hulls, masts, and kayaks.
• Wind energy: Reinforcement of specific parts of turbines.
• Civil engineering: Strengthening and retrofitting of concrete and infrastructure.
• Medical devices: Prosthetics, surgical instruments, and imaging equipment.
• Drones, robotics, armors, etc.

Why is carbon fiber the best material for hypercars?

In 1980 McLaren built the MP4/1, the first Formula 1 car with a carbon fiber monocoque chassis. Its success transformed motorsport, with every F1 team quickly adopting the technology — a standard that remains today.

Hypercars and supercars borrowed directly from this racing heritage and beyond body panels, carbon fiber is now used in monocoques, interiors, wheels, small components, and many more parts.

From Bugatti to McLaren and Koenigsegg, today’s hypercars rely on carbon fiber composites to achieve unmatched lightness, strength, and performance.

Strength to weight ratio

The performance of a car depends less on its absolute power than on its power-to-weight ratio. Since carbon fiber enables the necessary strength to be achieved at lower weight, it makes cars lighter and their power results in higher performance.

Rigidity and safety

Carbon fiber provides extreme stiffness while also offering excellent crash protection. Composite structures offer wide design possibilities to create tailor-made architectures that dissipate energy in a precisely calculated manner, offering outstanding protection for the occupants of the vehicle.

Prestige and exclusivity

Beyond performance, carbon fiber has become a symbol of cutting-edge technology and craftsmanship. Its distinctive woven look is instantly associated with hypercars, reinforcing their status as the pinnacle of automotive engineering.

Design optimization

Carbon fiber is anisotropic, meaning its strength varies depending on the orientation of the fibers. Additional layers can be added or removed to achieve higher or lower strength, and reinforcement can be applied only in the specific areas of a part where it is required. These variables, among many others, make it possible to optimize components in ways that are unattainable with other materials.

PROS & CONS of Carbon Fiber

Q&A

• Why is carbon fiber so expensive?
  Because its production involves costly precursors and complex processing, although for certain applications it is the more cost-effective option.

• Is FRP carbon fiber?
  Not always. FRP means Fiber Reinforced Polymer; carbon fiber reinforced polymer (CFRP) is just one type.

• Is carbon fiber a thermoplastic or a thermoset?
  The fibers are neither. Most composites use thermoset resins (epoxy), but thermoplastic versions also exist.

• Is carbon fiber stronger than steel?
  Yes. It can be as strong as steel while being about five times lighter.

• Can carbon fiber be recycled?
  Traditional composites are difficult to recycle, but new resins such as vitrimers allow reprocessing.

• What is a carbon fiber monocoque?
  A one-piece chassis made of carbon fiber composite, combining stiffness, lightness, and crash protection.

• Can carbon fiber parts be repaired?
  Yes, but repairs can be complex and require specialized techniques.

• Is carbon fiber always black?
  Usually, yes — but resins or hybrid fibers can add color.

• What is better, a fiberglass or a carbon fiber paddle?
  Carbon fiber is lighter and stiffer; fiberglass is cheaper and more flexible.

• Who invented carbon fiber?
  Edison made the first fibers in 1879, but modern high-strength fibers came in the 1960s.

• What is carbon fiber prepreg?
  Carbon fabric pre-impregnated with resin, ensuring quality and consistency, cured under heat and pressure.

Carbon fiber components, like this aerodynamic detail on a supercar, combine lightness, strength, and design precision to enhance performance.

TL;DR

• Carbon fiber can mean composite, fabric, or filaments. The most common meaning is composite: carbon fiber + resin.
• Epoxy resin + carbon fiber is the most common combination. Other resins like vinyl ester, phenolic or vitrimers are for very specific uses.
• Mostly made from PAN (polyacrylonitrile) via multi-stage process.
• Key properties: strength-to-weight ratio, stiffness, anisotropy, fatigue resistance, corrosion resistance, thermal stability, design flexibility.
• Applications: aerospace, automotive, marine, wind energy, sports, medical.
• All hypercars use a carbon fiber monocoque and body panels.
• Pros: performance, design freedom, prestige. Cons: high cost, recycling challenges, complex manufacturing.

The post What is exactly carbon fiber? appeared first on Managing Composites.

What is a Sandwich Structure?

A sandwich structure consists of two strong, stiff face sheets (skins) bonded to either side of a lightweight core. The skins carry the in‑plane tensile and compressive loads, while the core maintains the spacing between them increasing the momentum of inertia and resisting shear forces. This makes the structure particularly strong due to the way it distributes loads, working in a similar way to an I‑beam.

The sandwich structure is very simple, yet very effective, as it reinforces the material with a minimum increase in weight.

By separating the high‑strength material into outer layers, the bending stiffness increases dramatically without a proportional increase in weight. This is why sandwich structures are so widely used in sectors such as wind energy, automotive, and aerospace.

Core Materials for Sandwich Structures

The outer skins of a sandwich structure can be made from many different materials, including metals, but one of the most popular options is composites. For the core, there is also a wide range of materials that pair well with skins made from carbon fiber , aramid or glass fiber.

Foam Core Materials

One of the most popular core material is foam.

• PVC (Polyvinyl Chloride) foam is widely used because it is compatible with infusion, prepreg, and RTM processes, and it offers a very favourable balance of cost, processability, and mechanical properties.
• PMI (Polymethacrylimide) foam is another popular choice thanks to its excellent specific stiffness and its ability to withstand temperatures up to 180 °C (356 °F), making it highly desirable in automotive and aerospace applications.

Foams are widely used as core materials in composite sandwich structures.

Honeycomb Cores

Honeycomb cores have proven particularly effective for withstanding the loads experienced by the core. Several materials can be used in this configuration:

• Nomex® aramid honeycomb is very popular in high‑performance applications thanks to its excellent fire resistance, low weight, and dielectric properties.
• Thermoplastic honeycomb made from PET or polypropylene is used in lightweight applications requiring some degree of impact resistance.
• Aluminium honeycomb offers excellent thermal conductivity and compressive strength. While it is heavier than other options, it can be ideal where extreme lightness is not required. If combined with carbon fiber skins, a protective treatment must be applied to prevent galvanic corrosion from direct contact between the two materials.

Natural Core Materials

Two popular natural options for sandwich cores are:

• Balsa wood: the lightest known wood, with a long tradition in wind turbine blade manufacturing and marine applications. It must be sealed to prevent moisture absorption, but it offers excellent compressive strength.
• Cork: increasingly used for its outstanding acoustic and vibration damping properties, with the added benefit of being a renewable material.

Composite materials have unique characteristics thanks to the combination of two or more constituent materials. Their use in sandwich structures further enhances their mechanical performance by working in synergy with the core. This makes sandwich construction a valuable tool for engineers seeking to maximise the potential of materials for each specific application.

The post The Composites Heroes: Sandwich Structures appeared first on Managing Composites.

Processed basalt fibers in loose filament form, ready to be incorporated into composite materials

But it’s not the only fiber with the potential to transform materials engineering. Basalt fiber, produced by melting volcanic rock and extruding it into continuous filaments, has long been seen as a promising alternative — at least in theory.

The Promise of Basalt Fiber in Composites

On paper, basalt fiber composites can deliver many of the same advantages as carbon fiber composites:

• High tensile strength and good stiffness.
• Excellent chemical resistance, particularly to alkalis.
• Thermal stability and non-conductivity.
• A less energy-intensive production process compared to carbon fiber.

Basalt fiber also has some appealing environmental credentials, being derived directly from abundant natural rock. In theory, these benefits could make basalt a strong contender for applications in automotive, marine, or sports equipment — especially in contexts where the extreme stiffness of carbon fiber is not strictly necessary.

Why Basalt Fiber Never Went Mainstream in Composites Manufacturing

Despite its potential, basalt fiber has not achieved widespread adoption in high-performance composite manufacturing. Some of the challenges that have limited its popularity include:

• Lower stiffness than carbon fiber, making it less suited for applications where rigidity is critical.
• Heavier density compared to carbon fiber, affecting weight-sensitive designs.
• Limited availability of specialized processing know-how and supply chains compared to the mature carbon fiber industry.

As a result, while basalt fiber composites exist, they have remained a niche option rather than a mainstream engineering solution.

Finding the Right Niche: Concrete Reinforcement

Interestingly, basalt fiber has found a highly effective niche — not in aerospace or automotive, but in concrete reinforcement. In this application, its properties align almost perfectly with performance requirements.

• High tensile strength and crack-bridging capability help improve the ductility of concrete.
• Superior resistance to alkalis means basalt fiber does not degrade in concrete’s naturally alkaline environment, unlike glass fiber.
• Non-corrosive nature eliminates the rusting issues associated with steel reinforcement.

In reinforced concrete, basalt fibers can significantly improve flexural and tensile strength, reduce crack formation, and enhance durability — all without introducing corrosion risk. The result is a material that offers better long-term performance for infrastructure, marine structures, and other demanding civil engineering projects.

Natural basalt rock formation with its characteristic vertical columnar structures

From Unrealized Potential to Real-World Impact

Basalt fiber’s journey illustrates a truth often seen in materials science: the “best” material on paper isn’t always the one that dominates the market. Despite its early promise as a carbon fiber competitor, basalt has instead found a home in an entirely different industry, where its unique properties solve real, high-value problems.

And while basalt fiber composites have not yet rivaled carbon fiber in aerospace or supercars, research projects are ongoing, and at any moment something could be discovered that completely changes the situation. Meanwhile, basalt fiber has proven that, in the right context, it can be the perfect material for the job.

The post Basalt fiber: From Carbon Fiber Alternative to a Perfect Match for construction appeared first on Managing Composites.

In recent years, Artificial Intelligence (AI) has moved from being a promising concept to becoming a practical tool in manufacturing environments. In composite materials production, its potential is particularly significant due to the complex, heterogeneous nature of these materials.

With a computer vision and image analysis system powered by AI, it is possible to perform the same quality control as with traditional manual or automated methods, but faster, easier, and with greater precision. In addition, it enables many other capabilities that were previously impossible.

Pinholes are among the many defects that are automatically detected, measured, and classified.

For this reason, at Managing Composites we launched ESEN·EYE as a way to continue expanding the potential of composite materials and explore solutions that would not otherwise be possible.

From Sampling to Full‑Production Inspection

In many production settings, only a sample of parts is inspected in detail, due to time and resource constraints. This approach carries an inherent risk: undetected defects in uninspected parts.

Automatic generation of part quality reports provides absolute traceability for any conforming or non-conforming part

An AI‑driven inspection system can analyze 100% of the parts without slowing down production. This not only improves quality assurance and reduces the likelihood of defective parts reaching the final assembly stage, but also provides a visual record of the condition of every part at the time of manufacture. This enables complete traceability for each manufactured component.

Objective and Repeatable Measurements

Human visual inspection is subject to variability caused by fatigue, differences in experience, or subjective interpretation of defect criteria. By contrast, computer vision systems apply the same inspection rules consistently, regardless of operator or shift. This removes subjectivity from the process and enables quantitative, traceable quality metrics.

Early Detection and Feedback Loops

One of the strengths of computer vision technology is its ability to provide real‑time feedback. When integrated into the production line, an AI analysis system can immediately flag a deviation, enabling process adjustments before further parts are affected.

In a center line matching report, every distance is precisely measured to evaluate, numerically, the accuracy of the fiber placement.

This helps reduce scrap, rework, and associated costs, while also shortening the time between defect occurrence and corrective action. This reduces the number of parts manufactured outside tolerance, avoiding delays, cost increases, and unnecessary environmental impact.

The technology developed in ESEN·EYE inspects in real time for pinholes, fiber orientation, center line matching, possible contaminations, aesthetic defects such as scratches, and much more. For more information, you can visit the ESEN·EYE website to learn more about its applications in composite part manufacturing.

The post How can Artificial Intelligence improve composite parts? appeared first on Managing Composites.