Stronger than steel and a fraction of the weight, Carbon Fiber alone is an epic invention. Not to mention all the inventions it adds to, it’s no doubt that it’s one of our favorite materials. As a product design firm who brings products to life and improves existing products, the goal is often the same – make it stronger, lighter, and more durable. But for such a miracle material, how much do you really know about it? Let’s geek out for a minute and discover some things about carbon fiber that you may not have known.

1. To Make Carbon Fiber, Head to the Freezer.

The glossy woven rolls of carbon fiber are filled with a resin and backed with adhesive. The combination is stored at zero degrees Fahrenheit – any warmer and the resin will harden. That temperature sensitivity also means you must keep it cool and malleable to shape it. Even then, the clock is ticking. From the time the first weave of these plastic carbon threads is cut, you have about a day to shape it.

To ensure that the first layer of carbon fiber conforms to the desired mold, you seal a sheet in plastic and suck out any air pockets between layers. Think of how your duvet shrinks down when placed inside a storage bag and the air pulled out. This process is completed several times over again until the desired thickness is achieved. A product design firm would use this process when testing different versions of prototypes for various weights and strengths.

2. The First Carbon Fiber was Bamboo

   The carbon fiber engine used by Rolls Royce Aircrafts.

The first carbon fiber was used by Thomas Edison when he was experimenting with light bulbs in 1879. The carbon fibers were created by heating bamboo, which were fire-resistant – pretty ideal for any electricity experiment.

Almost a century later The Royal Aircraft Establishment at Hampshire, UK developed carbon fibers that were super strong. This version was used by Rolls Royce while manufacturing their aircraft engines. Modern carbon fibers are made from ployacrylonitrile, rayon or petroleum pitch – all readily available at any prototype and product design firm.

3. You Can Now 3D Print with Carbon Fiber

   The new carbon fiber 3D Printer.

Most 3D printers on the market produce items that look awesome but aren’t exactly made to withstand a lifetime of wear and tear. The Mark One 3D Printer is changing that as the world’s first 3D printer using composite materials. This includes creating carbon fiber, fiberglass, and nylon items. The vast capabilities of 3D printers, now combined with the durability of carbon fiber, is sure to have any product design firm eager to get this in the office!

For a little more details on how it’s made, check out this video on carbon fiber car parts.

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