Executive Summary
Aerolite Carbon Fiber is a groundbreaking material designed to bridge the gap between affordability and high performance in advanced composites. Its proprietary thermoplastic alloy resin and carbon fiber textile construction enable superior formability, strength, and aesthetics. Compatible with existing thermoforming equipment, Aerolite Carbon eliminates the need for specialized tooling, reducing costs and increasing accessibility. This paper explores its unique properties, applications, and transformative potential across industries.
Introduction to Aerolite Carbon Fiber
Aerolite Carbon Fiber combines a carbon fiber textile base with a proprietary thermoplastic alloy resin. The material is engineered to meet modern manufacturing demands for lightweight, durable, and versatile composites. Aerolite Carbon enables the production of complex geometries in a single step, making it a cost-effective alternative to traditional carbon fiber.
Material Properties
Standard Sheet Dimensions
Length: 2440 mm (96 inches)
Width: 1220 mm (48 inches)
Thickness: 1.5 mm and 2.5 mm (custom sizes available for large orders).
Carbon Content:
C30: 30% carbon by weight.
C15: 15% carbon by weight.
Physical Properties
Property C15 C30
Density 1.02 g/cm³ 1.19 g/cm³
Forming Temperature 165–195°C (330–380°F) 165–195°C (330–380°F)
Shrinkage Rate <1% <1%
Mechanical Properties
Property C15 C30
Tensile Strength 115 MPa (16.6 ksi) 200 MPa (29.0 ksi)
Tensile Modulus 6450 MPa (935 ksi) 12900 MPa (1870 ksi)
Flexural Strength 180 MPa (26.1 ksi) 253 MPa (36.6 ksi)
Flexural Modulus 6800 MPa (986 ksi) 13100 MPa (1900 ksi)
Performance Advantages
Lightweight Strength:
Aerolite C30 provides 7× the specific tensile strength and 5.8× the specific flexural modulus of thermoplastic polyolefin (TPO).
Aerolite C15 achieves 4.8× and 3.4× the same metrics, respectively.
Thermoforming Capability:
Forms sharp angles and deep draws using existing equipment, streamlining manufacturing processes.
Aesthetic Flexibility:
Supports molded textures, embossments, and decorative finishes without secondary operations.
Applications
1. Automotive Industry
Cost-effective alternative for under-hood components and lightweight body panels.
Provides high strength and premium aesthetics at a fraction of the traditional carbon fiber cost.
2. Transportation
Lightweight panels and components reduce vehicle weight, improving fuel efficiency and payload capacity.
3. Sporting Goods
High-performance applications like helmets, rackets, and bicycles benefit from lightweight strength and durability.
4. Electronics
Durable and lightweight casings for electronics requiring impact resistance and thermal stability.
5. Medical Devices
Used in specialized applications requiring rigid yet lightweight materials, such as prosthetics.
6. Consumer Goods
Guitar cases and similar products gain durability and premium performance without prohibitive costs.
Market Positioning and Sustainability
Aerolite Carbon is designed to overcome traditional barriers to carbon fiber adoption, such as high costs and specialized equipment. Its compatibility with existing infrastructure lowers production costs and allows manufacturers to offer premium products at accessible price points. Additionally, Aerolite Carbon’s lightweight properties contribute to fuel efficiency and reduced material waste, aligning with sustainable manufacturing goals.
Conclusion
Aerolite Carbon Fiber marks a significant step forward in composite material technology. Its blend of affordability, versatility, and high performance positions it as a leading material for industries requiring lightweight and durable solutions. With potential applications spanning automotive, sporting goods, and consumer products, Aerolite Carbon is set to reshape the future of manufacturing.
