Exploring Forged Carbon Fiber: Versatile, Cost-Effective, and Lightweight

Exploring Forged Carbon Fiber: Versatile, Cost-Effective, and Lightweight

Carbon fiber is one of the most sought-after materials in industries ranging from aerospace to automotive, thanks to its impressive strength-to-weight ratio. However, traditional carbon fiber, made from long continuous fibers, can be expensive and challenging to mold into complex shapes. Enter chopped strand forged carbon fiber—a game-changer that delivers the strength benefits of carbon fiber while offering increased versatility and a lower cost. Here at Covalo Industries we specialize in the processing of forged carbon for an array of applications.

What is Chopped Carbon Fiber?

Chopped carbon fiber is a composite material made by cutting long strands of carbon fiber into short segments, typically ranging from 3mm to 25mm in length. These short fibers are then mixed with a resin or polymer matrix to create a material that can be easily molded into various shapes and structures. The randomness in the fiber orientation (compared to traditional carbon fiber’s tightly woven structure) allows for increased flexibility in design.

While forged carbon fiber doesn’t have the same structural integrity as long carbon fibers in certain applications, it still offers mechanical properties like those of steel, such as enhanced stiffness, strength, and resistance to fatigue. In fact, specialized processes can be utilized to integrate long strands into the mold to increase the overall strength of the part. Virtually, this is generating a forged carbon fiber part with localized increases in tensile strength. Results have shown this technique to increase the overall strength of chopped forged carbon fiber parts, to comparable levels as conventional fabric formed parts. It’s essentially the middle ground between full carbon fiber sheets and cheaper, less durable materials.

Figure 1: Chopped Carbon Fiber Strands

 

Advantages of Forged Carbon Fiber

1. Cost-Effective:
   Chopped carbon fiber is more affordable than traditional carbon fiber weave because it uses shorter fibers and is easier to manufacture. The process doesn’t require the precision of continuous fibers, so it’s more accessible for industries and consumers looking for carbon fiber materials at a lower cost.
2. Lightweight:
   Like its long-fiber counterpart, forged carbon fiber remains incredibly lightweight. This makes it an attractive choice for manufacturers in industries where reducing weight is key to performance, such as automotive, sports, and aerospace applications.
3. Enhanced Durability:
   Even though chopped fibers aren’t as strong as continuous fibers, they still offer a much better strength-to-weight ratio than many other materials. Forged carbon fiber helps enhance the durability of the finished product while maintaining its lightness, making it perfect for applications that require impact resistance and durability without adding unnecessary weight.
4. Versatility in Applications:
   One of the key benefits of forged carbon fiber is its adaptability. It can be mixed with various resins to create products of different shapes and sizes. From automotive body panels to sporting equipment like helmets, to 3D-printed parts, chopped carbon fiber is often used in products that require a high level of customization.
5. Improved Performance Over Non-Carbon Materials:
   When compared to glass fibers, fiberglass, or other composite materials, chopped carbon fiber offers better mechanical properties such as improved stiffness, lower density, and superior resistance to wear and tear. As a result, manufacturers can achieve higher-performing products at a reduced weight without the need for premium-priced carbon fiber.

 

Applications of Chopped Carbon Fiber

1. Automotive Industry:
   Chopped strand forged carbon fiber is increasingly being used in car manufacturing, particularly in lightweight parts like interior panels, under-the-hood components, and bodywork. It’s an attractive choice for manufacturers aiming to reduce the weight of vehicles for better fuel efficiency and performance.
2. Sporting Goods:
   In sports equipment, chopped carbon fiber can be used in items like golf clubs, tennis rackets, and bicycle frames. The material’s low weight combined with its strength helps athletes gain an edge, whether it’s a faster swing or more efficient pedaling.
3. Consumer Goods:
   Chopped carbon fiber is not just for high-end industrial applications; it’s also finding its way into consumer products. From phone cases and laptops to watches and drones, this material offers a sleek, modern aesthetic along with the robust characteristics of carbon fiber.
4. Aerospace:
   The aerospace industry also benefits from forged carbon fiber components, particularly in weight conscious structures, like seat framing, brackets and linkage rods. Its ability to withstand high stresses while keeping weight low is vital for aircraft performance and fuel efficiency.

 

Figure 2: Forged Carbon Fiber Plate

 

Challenges of Chopped Carbon Fiber

While forged carbon fiber offers many benefits, it does have a few limitations. The main drawback is that the short fibers don’t provide the same level of strength or stiffness as long, continuous carbon fibers. As a result, chopped carbon fiber composites might not be suitable for high-performance applications where maximum strength is required.

Additionally, because the fibers are chopped, achieving consistent mechanical properties across the final product can sometimes be more challenging. Variability in fiber orientation and distribution can affect the material’s overall performance, making quality control essential.

 

Is forged composite better than woven carbon fiber?

Forged carbon fiber has a higher fiber volume content compared to woven carbon fiber. Additionally, forged carbon fiber follows no specific weave pattern, giving it a higher variation in how the fibers are oriented. This enables the ability to form complex 3-dimensional shapes.

Is forged carbon fiber stronger than steel?

Steel is generally considered the standard for industrial parts due to its strength to weight ratio. However, carbon fiber is taking over because it’s actually far stronger than steel. So long as you partner with a manufacturer capable of producing carbon fiber parts in a cost-effective manner, forged composite is the superior choice.

Does forged carbon fiber rust or scratch?

One of the greatest advantages of forged carbon fiber is that it is water-resistant, corrosion-resistant, and very scratch-resistant. The resin solution utilized for the application is critical to maintain the quality of the part. At Covalo industries we utilize multiple approved suppliers to ensure the best products are selected for the job. This means your carbon fiber parts will never rust like steel parts do, and they will continue looking like new for longer.

Is forged carbon cheaper than carbon fiber?

There is not a significant difference in the cost of materials between carbon fiber and forged carbon fiber, but forged composite is considered superior in strength and durability, especially when working with complex shapes. Our team will happily provide you with a quote if you’re interested in assessing costs.

Why Choose Covalo Industries for Forged Carbon Fiber Parts?

We have extensive cross-industry experience from automotive to aerospace. And we produce results on-time and accurately, thanks to our team of skilled engineers and designers. As a manufacturer of custom carbon fiber parts and products, Covalo Industries specializes in crafting durable carbon fiber components that perfectly conform to your specifications. All parts are manufactured identical to your supplied 3D model or 2D drawing.

Our in house forming capabilities for forged carbon fiber include pressure molding and skinning. We have various methods of mold fabrication from precision machined molds to high temperature epoxy molds. Our internal process and standard work allow us to offer both aesthetic high quality parts or light weight structural members.

We manufacture and supply formed  forged carbon fiber components as well as carbon fiber sheets.

Are You Ready to Get Started?

The next step in producing your forged carbon fiber parts is to discuss your components with our team of engineers so that we can provide an accurate quote with cost and lead time.

Conclusion

Chopped carbon fiber is a versatile, cost-effective alternative to traditional carbon fiber composites. It provides many of the same benefits—lightweight, durable, and high-performance—while being more affordable and easier to work with. Whether you’re building a high-tech sports car or looking for a rugged yet stylish consumer product, chopped carbon fiber offers a great balance between performance and cost, making it an appealing option across a wide range of industries. As manufacturing processes continue to evolve, chopped carbon fiber will likely play a significant role in bringing carbon fiber’s benefits to a broader audience.