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.

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