LenRun

Autoclave Processing Workshop

（A）Core Positioning
Custom Manufacturing Center for Large-Format Carbon Fiber Products

Our autoclave facility specializes in the custom production of large-format, complex-geometry, high-precision cosmetic components, primarily serving automotive exterior and aftermarket parts, drone fuselages, marine structural elements, large carbon fiber plates/sheets, and other applications demanding superior surface weave appearance, texture, and uniform load distribution.

Leveraging mature autoclave processing technology with tightly controlled parameters (temperature 80–180 °C ±5 °C, pressure 0.8–2.0 MPa ±0.05 MPa), we provide end-to-end solutions from design optimization to volume production, effectively addressing the key challenges of forming large composite parts: processing difficulty, inconsistent properties, and surface defects.

（B）Production Workflow
(1) Precision Material Preparation – Optimized ply kits cut from 3D data; material scrap kept <5 %.
(2) Directional Layup & Debulk – Layer-by-layer placement with intermediate vacuum debulking to remove air and improve consolidation.
(3) Vacuum Bagging & Leak Check – High-temperature film bagging, pulled to –0.095 MPa and held 20–30 min for leak verification.
(4) Precision Cure – Customized profile (typical epoxy: 120 °C / 2 h / 1.2 MPa) with active air circulation for uniform resin cure.
(5) Controlled Cooling & Demolding – Parts cooled below 50 °C before removal to prevent distortion from resin shrinkage.
(6) Final Finishing – High-precision trimming, sanding, and coating as required—delivered assembly-ready.

（C）Key Process Advantages

（a）Core Technical Strengths

1. Uniformity Assurance: High-velocity circulating hot air and gas pressurization maintain vessel temperature variation ≤ ±3 °C, with pressure applied evenly across part surfaces. This effectively resolves issues in large components (up to 2000 mm × 4000 mm) such as uneven stress distribution, localized weakness, and irregular weave patterns, improving first-pass yield and minimizing rework.

2. Precision Control: Real-time PLC monitoring of temperature, pressure, and vacuum, combined with custom steel, aluminum, or high-temperature resin tooling, delivers dimensional accuracy of ±0.1–0.5 mm and surface roughness Ra ≤ 0.8 μm, significantly reducing secondary finishing requirements and associated costs.

3. Material Flexibility: Compatible with 3K/6K/12K carbon fiber, spread-tow carbon fiber, forged carbon fiber, fiberglass, and aramid prepregs in woven or unidirectional form. Supports lightweight foam cores, colored fabrics, matte/gloss finishes, and other cosmetic options to meet diverse aesthetic and performance needs across visible and high-end equipment applications.

（b）Precise Comparison with Compression Molding

(1) Application Scenarios
1. Autoclave: Ideal for large-format and complex shapes such as automotive panels, drone bodies, large luggage shells, marine structures, and large carbon fiber sheets.

2. Compression Molding: Better suited to small, high-strength structural parts like bicycle pedals, phone cases, drone landing gear, and propellers.

3. Selection Guidance: For volume production of large visible or structural components, autoclave processing avoids the size constraints of compression molding and reduces tooling costs. It is the preferred choice for parts >500 mm or where surface finish and dimensional consistency are critical.

Shaped Components	Car Parts

（2）Core Performance Characteristics
1. Autoclave: Excellent size scalability, uniform surface quality, and balanced stress distribution – ideal for larger parts requiring high cosmetic and dimensional consistency.

2. Compression Molding: Superior localized strength, though weave alignment is more difficult to control precisely – best for small parts prioritizing structural performance.

Pregreg Preparation	Load into Autoclave for Cure

（3）Objective Notes & Mitigation Measures
1. Process Limitations: Higher initial equipment investment, longer per-cycle times, and consumption of vacuum bagging consumables (bags, breather) result in greater energy and time use compared to compression molding.

2. Customer Assurance: For high-volume orders, we employ parallel autoclave runs and standardized tooling to shorten lead times by 20–30 %.

Remove from autoclace	Demolding

（D）Why Partner with Us?
•  Technical Confidence – 23 years of composite experience and a dedicated autoclave team that rapidly resolves common issues (warpage, surface imperfections, etc.).
•  Capacity Assurance – Three autoclaves of different sizes enable parallel runs and flexible scheduling to meet your deadlines.
•  Service Excellence – Complete turnkey support: 3D optimization → tooling → prototypes → volume production → after-sales follow-up, with a single point of contact throughout.

Twill Weave	Plain Weave	Forged Carbon	Spread Tow Woven

If you are facing challenges with large carbon fiber components—forming difficulty, cost control, or quality consistency—simply send us your 3D files. We will provide a free detailed manufacturing proposal and accurate cost estimate to help you achieve superior products and stronger market positioning.

We look forward to supporting your next project.