Detailed Description
Feature - Female-mould hand layup of T300-grade carbon/epoxy prepreg, autoclave cured with controlled pressure and temperature to manage porosity and fibre volume fraction. Ply schedules are defined per part thickness and load path; symmetric or quasi-isotropic layups are selected against the specific stiffness requirement of each bracket, link or shell.
Advantage - Compared with aluminium, the laminate reduces part mass while keeping torsional rigidity and fatigue resistance. Local pad-up around inserts avoids stress concentration. Batch consistency is maintained through prepreg cold storage, controlled cure cycles and CNC machining with vacuum fixture and diamond-coated tooling.
Benefit - Engineers receive traceable parts with repeatable dimensions and documented layups, cutting rework during assembly and supporting scale-up from prototype to production without requalification delays.
Engineering concerns covered: layup design - ply orientation and stacking sequence are specified per load case, not copied from a catalogue; porosity control - autoclave cure cycle and vacuum integrity are logged for every batch; batch consistency - prepreg lot, mould ID and cure record travel with the shipment; CNC delamination prevention - diamond-coated tools, vacuum clamping and through-lubricated drilling with backing support protect bearing holes; temperature / ageing - service temperature range, sterilisation compatibility and fatigue conditioning data Confirm with supplier.
Specifications
|
Item |
Value |
|---|---|
|
Process |
Hand layup of prepreg on female mould + autoclave cure |
|
Material system |
T300-grade carbon / epoxy prepreg, 3K plain weave |
|
Part types |
Links, side plates, shells, brackets, end-effector arms |
|
Size envelope |
up to 4000×2000mm in the router envelope; tool-dependent |
|
Wall thickness |
1.5–5.0mm typical; local pad-up at bosses |
|
Tolerance |
±0.15mm on moulded profile, ±0.10mm on machined interfaces |
|
Inserts |
Bonded stainless/aluminium bushes, threaded plates, metallic bearing seats |
|
Surface |
Natural 3K twill, matte clear, or medical-grade coating (Confirm with supplier) |
|
Tooling |
Female/male moulds produced in-house; tool ownership stated in the quotation |
|
Certification |
ISO9001, CE (factory); biocompatibility, material and fatigue reports Confirm with supplier |
Applications
Medical rehabilitation robot thigh/shank links and hip-joint side plates; lower-limb exoskeleton frames and back-support shells; rehabilitation training end-effector brackets; high-end industrial equipment custom-shaped load-bearing components and robot structural parts.
Why Choose Us
Two things decide a project like this: whether the ply book matches your load case, and whether part fifty matches part one. We hold both in writing-ply schedule, mould ID, prepreg lot and cure record travel with the parts, which is what lets you extend a production run without re-qualifying blind. Testing is only ever provided where it was actually run; anything not measured is marked Confirm with supplier rather than filled in. Shipments are exported on true declared description. Guangdong Shenyang New Material｜ISO9001 & CE certified dry carbon composite manufacturer based in Huizhou, China. Equipped with autoclave, 4.0m×2.0m large-format CNC router and prepreg cold storage. Products for legal export, prototype & mass production available, batch performance traceable.
FAQ
Q1.Can you reverse-engineer layup from my load spectrum?
A1.Yes. Provide joint torques, limit loads, safety factor and interface geometry; we return a layup proposal with local thickening recommendations.
Q2.Can carbon fiber parts replace aluminium links directly?
A2.Slots cut into aluminium do not copy to carbon. We redesign for equivalent stiffness and add bonded metal inserts where bearing loads concentrate.
Q3.Why not use standard carbon sheets for exoskeleton frames?
A3.Carbon fiber layup stiffness scales with ply angle and symmetry; standard sheets cannot match directional stiffness without redesigning the ply book for each joint.
Q4.Should I choose prepreg or pultruded profiles for robot arms?
A4.Prepreg autoclave parts suit complex shells and bonded inserts; pultruded profiles suit straight guides. We match process to geometry after reviewing your drawing.
Q5.Are mirror-finish surfaces available for medical exteriors?
A5.Mirror finish on carbon laminates risks micro-crack visibility and peel; matte clear or medical coating is preferred. Mirror option Confirm with supplier per resin.
Q6.MOQ and lead time for custom-shaped carbon parts?
A6.Tooling and first-article lead time depend on part size and quantity. Prototypes and mass production are quoted separately; Confirm with supplier.
Q7.Do you provide batch test reports for production orders?
A7.Actual test reports are supplied where performed; untested items are marked Confirm with supplier. Batch traceability covers prepreg lot, mould ID and cure record.
Q8.What engineering data should I send for a quote?
A8.Send load limits, safety factor, operating temperature, interface drawing and target quantity. We then propose layup, thickness and insert scheme.
Q9.End-use declaration required before quoting?
A9.Yes. Destination, application and compliance documents are required for legal export. We do not proceed without confirmed end-use information.
Q10.How are inserts bonded into carbon fiber structures?
A10.Metal bushes or plates are bonded with structural adhesive after surface preparation. Fit, adhesive type and cure are specified per load and environment.
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