Forged Carbon – the smart material for lightweight, robust applications

Discover Forged Carbon – the ultra-lightweight, high-strength composite material made from carbon fibres. Overview of advantages, areas of application, production and sustainability.

What is Forged Carbon?

Forged Carbon is an innovative composite material consisting of short, non-directional carbon fibres that are bonded together into a solid, complete solid using a special pressing and curing process.

What makes Forged Carbon special?

Compared to conventional carbon fibre composites, Forged Carbon offers high strength at low weight, excellent impact resistance and cost- and resource-efficient production.

What are the main advantages of Forged Carbon?

• Very high strength-to-weight ratio
• Excellent impact strength and shock resistance
• Good abrasion and fatigue resistance
• Cost-efficient manufacturing with short production cycles
• Flexible shaping, complex geometries possible
• More environmentally and resource-friendly than some classic fibre composites

How is forged carbon made?

Forged carbon is made by pressing short carbon fibres, resins and fillers into a homogeneous mass, which is then hardened. The result is a flame-retardant, durable material with very low porosity and excellent strength.

What is forged carbon used for?

• Automotive and motorsport parts (body parts, interior components)
• Sports and leisure equipment (helmets, protective gear, bicycles)
• Aerospace components (housings, structural parts)
• Furniture and design objects (deep-drawn moulded parts with high strength)
• Tool and industrial components (housings, handles)

What does forged carbon offer compared to conventional carbon fibre composites?

• Forged carbon offers similar or better strength values with lower porosity.
• Production is often faster and less resource-intensive.
• More flexible shaping without expensive preforms or time-consuming needle punch processes.

How sustainable is Forged Carbon?

• Less material loss due to more efficient manufacturing.
• Longer service life due to high impact and fatigue strength.
• Recyclability depends on the resin system used; possibilities exist depending on the resin type.

What are the advantages of forged carbon?

• Strength and weight requirements of the application
• Mould complexity and surface quality
• Cost budget and production volume
• Environmental and sustainability goals

How is forged carbon processed?

Discover the processes in our technician blog!