What to Look For in a Custom Carbon Fiber Parts Supplier

Certifications and Quality Control

The aerospace industry operates under stringent regulatory standards that ensure all parts and processes meet the highest levels of safety and reliability. When selecting a carbon fiber parts supplier, it’s crucial to verify that they hold relevant certifications, such as AS9100, which is the standard specifically designed for the aerospace sector. This certification ensures that the supplier adheres to a comprehensive quality management system that covers all aspects of production, from material handling to final inspection.

Furthermore, robust quality control processes are non-negotiable. A dependable supplier should have a well-documented quality control system that includes regular audits, process validations, and product inspections to maintain high standards throughout the manufacturing process.

• Re:Build Cutting Dynamics carries all the credentials needed for flight-critical applications, including AS9100 certification, ISO 9001:2015 certification, and being ITAR compliant.

Experience with Defense/Aerospace Applications

Not all carbon fiber manufacturers will have the necessary experience in the aerospace and defense sectors. These industries require components that can withstand extreme conditions and rigorous use. Therefore, it is essential to select a supplier with a proven track record in these fields. Experience in manufacturing carbon fiber parts for applications such as drones, missiles, aircraft interiors, and structural components is a testament to a supplier’s ability to deliver products that meet the exact requirements of these demanding applications. 

There are even more variables when it comes to the matrix materials used in aerospace thermoplastic composites. For example, Re:Build Cutting Dynamics has extensive experience with the following thermoplastic materials when working with composites:

1. Polyetheretherketone (PEEK): Exhibits excellent mechanical properties, heat resistance, and chemical resistance.
2. Polyamide (PA): Provides good strength, toughness, and processability.
3. Polyphenylene sulfide (PPS): Offers high thermal stability, chemical resistance, and dimensional stability.
4. Polyetherketoneketone (PEKK): Similar to PEEK, with improved mechanical performance, processing characteristics, higher fracture toughness, and resistance to crack propagation.
5. Polyethersulfone (PES): Offers good mechanical strength, thermal stability, and inherent flame retardancy. PES composites have excellent resistance to heat and chemicals.

The choice of matrix material depends on the specific requirements of the application, such as operating temperatures, chemical exposure, and desired mechanical properties. Aerospace manufacturers carefully evaluate these materials to optimize the performance and durability of their composite components.

Advanced Manufacturing Capabilities

The method of manufacturing carbon fiber components can greatly affect their qualities and performance. Leading suppliers should possess advanced manufacturing capabilities such as flat consolidation, continuous compression molding (CCM) from either raw tapes or pre-consolidated strips, traditional stamp/tool forming,  and 5-axis CNC machining. These technologies are pivotal in producing parts that are not only lighter and stronger but also more uniform and consistent in quality. Additionally, automated manufacturing processes can enhance production efficiency and scalability, reducing lead times and costs.

• Re:Build Cutting Dynamics has comprehensive precision machining capabilities, including traditional stamp/tool forming, CMM from either raw tapes or pre-consolidated strips, flat consolidation, and 3-, 4-, 5-axis CNC machining stations.

Material Versatility

Different applications may require different types of carbon fiber reinforced polymers, each offering unique properties. A supplier with the ability to work with a wide array of materials, such as PEEK, PEKK, and PPS, is advantageous. This versatility ensures that the parts can be optimized for specific performance requirements, making it possible to fine-tune the properties of the carbon fiber parts to meet precise operational demands.

• Re:Build Cutting Dynamics is an experienced manufacturer of a diverse array of thermoplastic composite products, which include carbon fiber parts woven with PPS, PEI, PEKK, and PEEK.

Engineering Support

The complexity of designing for carbon fiber materials means that engineering support is not just an add-on but a necessity. A supplier that offers design feedback, analysis, and engineering support can be invaluable. This support helps in optimizing the parts for the manufacturing process from the outset, potentially saving time and reducing costs by preemptively addressing production and performance issues.

• Re:Build Cutting Dynamics features a well-rounded and cross functional team able to take your project through every stage, including Design for Manufacturability (DFM) feedback, simulation, machining of tooling, prototyping, and final production—be it individual components or assemblies.

Re:Build Cutting Dynamics is a Leading Custom Carbon Fiber Parts Supplier

By prioritizing these factors aerospace and defense companies can secure a partnership with a carbon fiber parts supplier that meets their specific needs. The right supplier not only enhances the performance and reliability of the end products but also supports the overall mission of these critical industries.

For more than 30 years, Re:Build Cutting Dynamics has checked all these boxes—and more—to forge a reputation as a leading supplier of custom carbon fiber parts for aerospace and defense applications. As part of the Re:Build Manufacturing family, our comprehensive in-network resources give us all the tools to deliver the custom carbon fiber parts needed for your most critical applications. 

We’re ready to be your trusted custom carbon fiber parts supplier. Connect with our team today to learn more about the difference we provide.