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Originally Posted by Perfectlap
Why is it so expensive? the build process doesn't strike me as very scientific and the materials are hardly exotic.
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aside from materials, the build process to PROPERLY create carbon fiber components, especially structural components, is quite difficult. much of what's on sale in the way of body panels, bumpers, interior parts, etc. is made in more or less the same way as a fiberglass part. in this case, it's not much stronger or lighter or time consuming to construct.
on the high end, very tight controls on the mold (materials, temperature, humidity, etc.) are in place. where i work, we even went so far as to choose a metal that has the same thermal coefficient of expansion as the CF matrix has to prevent distortion.
once the molds have been created, the fabric must be layed up in a manner specific in fabric orientation (you cant' just stick the fabric on the mold). you actually have to choose in which dimensions you want the part to be strong.
application of the resin is a task in itself if one wants to eliminate porosity, boracity / de-lamination issues, etc. after the resin is applied, a vacuum bag is put in place over the mold to suck the fabric and resin together. in some instances, the CF matrix is actually under tension during this process (pre-stressed CF matrix). after this, the whole schebang is baked in an autoclave.
the methods above probably aren't used on your average bumper, but they are used in F1, carrera GT, enzo, etc.