Carbon Fiber
Carbon fiber is a high-performance composite material made from woven strands of carbon atoms, typically reinforced with resin. It belongs to a class of materials known as fiber-reinforced plastics and is formed by weaving carbon filaments into fabric, cutting it into shape, infusing it with resin, and curing it using processes like carbonization or graphitization. The result is an incredibly strong, lightweight material with one of the highest strength-to-weight ratios of any substance used in manufacturing.
Exceptional Strength-to-Weight Ratio: Carbon fiber is stronger than steel and significantly lighter, making it ideal for parts where both rigidity and low mass are essential.
High Modulus and Tensile Strength: With tensile strengths around 4,000 MPa and a modulus of ~400 GPa, it performs extremely well under load, especially in tension.
Chemical and Corrosion Resistance: Carbon fiber does not rust or degrade under most environmental conditions, making it suitable for use outdoors or in humid climates.
Thermal and Electrical Properties: It is resistant to high temperatures and, depending on the resin used, can be made electrically conductive—useful in grounding or shielding applications.
No Fatigue or Creep: Carbon fiber holds its shape over time even under constant stress, making it reliable in long-term, load-bearing designs.
High Cost: Carbon fiber is still expensive compared to aluminum or steel, limiting its use to specialized parts where weight reduction or stiffness are absolutely necessary.
Brittleness: While strong, it can be brittle—meaning it doesn’t deform before breaking. If overloaded, it may snap without warning.
Difficult to Machine: Carbon fiber is abrasive and wears down tools quickly. Cutting it typically requires carbide or diamond-coated tooling, and dust from cutting is hazardous to breathe.
Layer Direction Matters: Unlike metals, carbon fiber is anisotropic—it’s stronger in the direction of the fibers. Improperly oriented layers can lead to unexpected weak points.
Delamination Risk: Improper bonding or damage to the laminate layers can cause delamination, reducing strength and integrity.
When to Use It in FTC:
Carbon fiber is best suited for ultra-lightweight structural parts, such as arm extensions, sensor mounts, or camera booms, especially when weight is a design constraint. While not common due to cost and machining needs, carbon fiber can offer a performance edge if used thoughtfully and fabricated with care.
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