Carbonfiber nonwovens

Flexibility and drapeability:
Compared to other textiles, such as wovens or non-crimp fabrics, nonwovens are easier to drape and more flexible. Thanks to its good elongation properties in the X and Y directions, the fabric adapts ideally to a desired shape in edge and curve laying. This allows components with very complex geometries to be produced.

Fiber Alignment:
The orientation of the fibers in the nonwoven exists in X, Y and even Z directions. Thus, the carbon fiber nonwoven represents a quasi-isotropic 3D reinforcement textile which offers new possibilities compared to continuous fiber textiles.

Blending with other fibers possible:
Pyrolyzed as well as solvolyzed fibers can be processed into nonwovens. It is also possible to use blends of rCF with thermoplastic fibers. These can then be used in thermal pressing processes without further steps for the production of parts. After impregnation and consolidation, the thermoplastic fibers represent the polymer matrix system, which means that the addition of extra matrix material (e.g. polymer such as resin, etc.) is no longer necessary.

High surface quality:
By using carbon fiber nonwovens on the surface of components, very good surface qualities can be achieved. This effectively avoids forming of underlying textiles and the resulting uneven surfaces (e.g. pin holes, etc.). As a result, the amount of filler and paint preparation required can be minimized.

Mechanical bonding methods:
Two processes are used for nonwoven bonding, which can be selected according to requirements:

"Maliwatt stitch-bonding process":
The "Malitwatt stitch-bonding process" is already known in the field of technical textiles for (multiaxial) fabrics. The " stitching " improves handling and increases the maximum tensile forces in the direction of the yarn of the nonwoven fabric. In addition, the "needle channels" result in improved infiltration of the resin during the impregnation process. It is possible to vary the stitch yarn type, the stitch length as well as the type. In addition, further textiles can be applied and bonded on the top and/or bottom side. Fabric widths here range up to 1500 mm with basis weights from 100 g/m² to 350 g/m².

"Needle punching":
The mechanical bonding by needle punching is characterized that several needles with notches punch through the fabric layers to " interlace" them with each other. Mechanically bonded nonwovens can be draped very well. Fabric widths up to 2000 mm and basis weights from 100 g/m² to 600 g/m² can be manufactured.

Individual custom cutting and freedom of design:
Carbon fiber nonwovens can be supplied as individual cuts according to desired dimensions. Laser cutting technologies allow individual shapes. This enables the processing of textiles without the generation of residual materials. Offcuts are thus avoided and waste is reduced.

More information on carbon fiber nonwovens in the laser test:

• Unlimited design:
  Extraordinary design possibilities due to the material's freedom of construction and shape
• Unique optical effects:
  Attractive appearance of the surface due to the structure of the fiber distribution
• Individual color design:
  in combination with gel coatings, very smooth surfaces can be achieved and a wide range of colors can be realized
• Integral design:
  depending on the desired application, integrations such as inserts or channels for the laying of cables, wires, etc. can be directly included in the material
• Optics in elegant black:
  Carbon fiber nonwovens are black and therefore do not require separate coloring. The trend color black can be achieved in components without further coloring or painting.

• Recycling :
  The fibers as raw material for the rCF nonwovens are provided by carbon fiber processing industries as edge trimmings from fabric and non-crimp fabric productions. Furthermore, fibers from "end of life" components can also be used for nonwoven production.
• Circular return:
  By using 100% recycled fibers, no so-called "virgin carbon fibers" are used for production, therefore saves resources.
• Energy-saving production:
  Carbon fiber production is very energy-intensive. By using recycled fibers, the energy for a new fiber production is saved and thermal disposal is avoided.
• Improving the CO₂ footprint:
  The use of recycled fibers has a positive effect on the life cycle assessment (LCA) of components.

• Electromagnetic shielding:
  With the increasing importance of e-mobility, the demand for shielding technologies is rising in order to protect the many electronic components against harmful electromagnetic radiation (keyword EMI shielding). Carbon fiber nonwovens shield electromagnetic radiation. As a result, they can be used to protect sensitive electrical components.
• Resistance heating:
  Due to the electrical conductivity of carbon fibers, nonwovens can be contacted. When an electric potential is applied, they act as resistance heaters. This enables applications such as the heating of panels on walls, ceilings, floor panels, etc. for e.g. de-icing.
• Integration of mounting elements and electrical components:
  Mounting elements, such as nuts or screws as inserts, or even cables, wires, plates, etc. can be included in carbon fiber-reinforced plastic components during production.

Compared to "virgin carbon fiber" textiles, a cost advantage of rCF nonwovens of up to 70% can be achieved.

rCF nonwoven-reinforced components offer high weight savings compared to conventional construction materials:

• Compared with glass-fiber-reinforced components, up to 60% weight can be saved in the end product with the same performance.
• Compared to aluminum components, up to 70% weight can be saved in the end product with the same performance.