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Process
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Step 1: Design/Concept
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To bring
a carbon fiber component to market, the first step is to develop a
working design with an appropriate laminate schedule such that the
component being built is as light weight as possible, while retaining
functional structural integrity.
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Step 2: Mold Development
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Next, hand crafted molds are built using high temperature
gel coat and fiberglass. Alternatively, molds are made with
aluminum/steel which has been CNC
machined. Great care is taken to ensure that the molds are of the highest
quality, a crucial component of a well built structure.
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Step 3: Layup
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Part of what makes our Carbon Fiber so visually stunning is
the skill of our laminators. Proper layup of
composite materials into the molds, while adhering to
our strict laminate schedules, results in components that are
visually pleasing and structurally sound.
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Step 4: Vacuum Sealing/Autoclaving
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To provide superior compaction in comparison to other
methods of production, we vacuum bag and autoclave every piece produced.
Constant vacuum is applied to the component while it is curing, providing
evenly distributed pressure at high temperature.
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Step 5: Inspection
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Each piece is inspected for pinholes, nonlinear bias, and
any other defects. Anything which does not pass our strict standards of
quality is destroyed.
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Step 6: Trimming, Fitting, and Finishing
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Once a piece has passed inspection, it is trimmed using a
precise ROTT or trimline. At this stage, any
secondary bonding processes are completed, and each piece is QA tested
for fit on the actual component it is going on. The part is then hand
buffed to a mirror finish. It should be noted that none of our products
require or undergo any secondary finishing such as clearcoating,
which can accelerate yellowing due to UV damage.
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Step 7: Packing and Shipping
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Each piece produced is carefully packed and shipped to its
destination. Care is taken to ensure proper labeling, and custom
packaging is available.
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