About Maxton Carbon
The Carbon Division is the newest production branch at Maxton Design, which specialises in the creation of carbon fiber products. The department consists of highly trained employees who have expertise in working specifically with carbon fiber.
We thought it would be best to give you an insight into the production process and how it is managed at the official headquarters in Poland.
Of-course, the machinery differs from those used for our ABS plastic range. Maxton Design has invested in an autoclave, plotter, furnace, freezers, paint shop and even specially prepared temperature-controlled rooms.
Production
The production process is complex and lengthy. Firstly, a 3D scan of the vehicle is required, this collects data on the exact shape. The data is then used to construct digital 3D models and design products that provide a picture-perfect fit.
Once the design is approved a CNC-processing device makes the mould model from a special material that is resistant to high temperatures and pressure, this is then coated in carbon. The carbon coated mould is then placed in an autoclave where temperatures of 120°C and pressure (6 bar) cause the carbon to harden. After removing it, it is left to rest for several hours.
The same method of production is often used in Formula 1 and aviation. It is also worth noting that many of the hyper car manufacturers such as Bugatii, Ferrari and Pagani have adopted this process to manufacture their carbon parts.
After removing the unfinished product from the autoclave, the preparation can begin. Sanding, varnishing and polishing is required to ensure a perfect finish. The final stage is completed in a separate room where sterility is maintained so no dust is present.
Types of Carbon
There are numerous varieties of carbon fiber on the market. Maxton Design use prepreg carbon – these are large sheets of carbon soaked in resin. Carbon prepreg is a dry combination of carbon fabric with epoxy resin, which is hardened only after thermal treatment.
Prepregs, due to their nature, are sensitive to temperature and humidity, and therefore most of them are stored in low temperature. Thanks to the use of prepregs, the production process can be sped up and exposure to hazardous substances is also avoided.
The visual layer of carbon is 245g Twill which is the most popular size and weave pattern used in the automotive industry. This particular weave is 2/2, where the fibers intersect at a 90-degree angle, which ensures adequate stretch and strength, and at the same time a slick appearance.
Forged carbon is also an option, to create this, small pieces of the sheet are laid flat on top of each other without a specific pattern, which gives a unique appearance each time.
We are expecting 2023 to be the year of carbon at Maxton Design. Products are already in production for the RS6 C8 and BMW M4, with orders being dispatched as we speak. There are many more exciting projects in the works such as the BMW M3 and RS3 8Y, so keep your eyes peeled for what’s to come in the Carbon division.
