Blackwave is specialized in sheet moulding compound of carbon fiber reinforced plastics (Carbon-SMC). For more information on the process read HERE.
Utilizing the Carbon-SMC process, Blackwave produces complex parts which can’t be manufactured by conventional processes. The short cycle times and highly automated process enables repeatable quality and guarantees an economical production of lightweight components.

Blackwave realizes an economical substitution of complex metallic lightweight components through CFRP

Advantages

Low density

Complex
3D geometries

Repeatable high quality

Mechanical performance

Cost efficient production

Short cycle times

Less waste

Appealing haptics and apperance

Carbon Sheet Moulding Compound (Carbon-SMC) is a process for manufacturing long fibre-reinforced parts which is fundamentally different from conventual processes. Nevertheless, parts with highest stiffness and strength are manufactured. The mechanical properties of Carbon-SMC compare to those of high performance aluminum alloys with 45 % less density at the same time. Also, the low coefficient of thermal expansion (CTE) can be compared to that of Invar.
Since Carbon-SMC is a compression molding process, complex parts are manufactured in a reproducible manner. This leads to significant advantages when designing a component: the engineer has numerous possibilities of integrating ribs or changes in wall thickness into the part which parts for conventional CFRP processes do not have. This way, components can be tailored to load cases and become even lighter and have more performance. Even attachment points and load application elements can be integrated into the part during manufacturing. Since the process is highly automated, it enables high lot sizes of reproducible components in high quality. Because Blackwave is working very efficient, hardly any waste is produced during the manufacturing.

Typical material properties of Carbon-SMC

Tensile strength
Young’s modulus
Density
Glass transition temperature
Thermal expansion

280 MPa
42 GPa
1,5 g/ccm
150 °C
3 µm/mK

Production process

Cutting and preforming of the material

Inserting the preform into the heated mold

Flowing of the material under pressure

Curing of the component in the final shape

Removing the finished part from the mold

Trimming and individual processing

In the process of Carbon-SMC (Carbon Sheet Moulding Compound), a mixture of carbon fibre and thermosetting resin are processed in a press tool. To create the compound, carbon fibre chips with lengths from 25 to 50 mm are impregnated with a thermoset plastic on a flat-track system. The fibre volume content is adjusted in such a way that the requirements of the component are met.

  1. Blanks are produced from the flat semi-finished product by means of a CNC cutter and a preform is then produced. The weight of the preform is adjusted precisely.
  2. Subsequently, the preform is positioned in the heated mold which is then closed under high pressure.
  3. During the molding process, the material flows into the cavity of the tool and fills it completely. This results in the final component geometry filled with the fibre and resin mixture.
  4. The material cures under high pressure and temperature.
  5. After the component is completely cured, it is mechanically ejected. The tool is ready for the next cycle.
  6. With the component molded in its final geometry only a minimum trimming effort is necessary. Eventually this step is followed by project specific processing.