If you’ve been browsing our material catalog and any plastic or metal we offer just doesn’t seem quite to fit the bill, this article is for you. Composite materials are the oddballs of the material world; entirely different from Metals, Plastics, and one another to a point that they are practically incomparable. In this article, we will break down the five composites we offer: ACM, Carbon Fiber, Cork, G10/FR-4, and Le Phenolic, and try to make sense of what these materials are best used for.
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Cutting process: CNC Routing
Pros:
ACM also known as e-panel or DiBond® is a low-cost, lightweight cousin of aluminum. We offer the material in matte white, matte black, and brushed allowing you to obtain the strengths and aesthetics of aluminum at half the weight. Composed of two sheets of aluminum sandwiched with a polyethylene core, this fire-resistant composite is made out of 80%+ recycled materials making it as sustainable as it is good-looking.
Cons:
As with many of the composites we offer, this material can’t be deburred, bent, tapped, or powder coated and isn’t particularly easy to machine by hand due to the sandwiched nature of its construction. It also can’t be welded in the way that traditional aluminum is so be wary of that if you are a metalworker looking to use ACM as an aluminum alternative.
Typical Uses:
Cutting process Waterjet
Pros:
Carbon Fiber has exploded in popularity over the last few years taking over our cars, bikes, and wallets with good reason. The composite offers an unmatched marriage of strength, rigidity, and light weight to be stronger than steel at a fraction of the weight. Our 2×2 twill weave offering is matte finish, corrosion-resistant, and absorbs impact energy due to its remarkable rigidity. If you are looking for an application that demands some extreme strength, we can’t recommend carbon fiber enough. Additionally, the material we use is a much higher quality than the aesthetic trim pieces you see in many cars nowadays so we recommend diving further into the material and its attributes if you are uninitiated.
Cons:
The biggest advantage to Carbon Fiber is also often its biggest downside depending on your application. The material is so unfathomably rigid that it can often cause problems in larger mechanisms and structures that are designed to flex. While it absorbs impact quite well itself, it can often direct that impact into attached parts which is something to look out for. The other thing to be careful with when choosing carbon fiber is it’s cost and machinability. The material, especially at higher thicknesses, can get expensive since it becomes increasingly difficult to produce and manufacture as it gets thicker. Because of the cost factore and the way the material is laid, we don’t recommend using this for applications/prototypes that are going to require a lot of machining on your end as drilling holes or cutting it is both quite difficult and can sacrifice a lot of the material’s integrity if not done correctly. If you are doing a large, untested order in carbon fiber, we highly recommend ordering a prototype in an alternate material to make sure everything fits together exactly as needed and before transitioning to carbon fiber. We often consider a test run like that an insurance policy on a substantial order and has saved us on our own projects time and time again. Carbon fiber also cannot be Deburred, Bent, Tapped, or Powder Coated due to its rigidity.
Typical Uses:
Cutting process: Laser Cut
Pros:
Cork is somewhat an oddball material even inside of the diverse composites lineup. While most of the materials we offer are meant to serve some sort of structural function, cork is used almost exclusively for seals, aesthetics, and impact/vibration dampening. The material is incredibly workable, attractive, leak-free, and durable in addition to being one of our most sustainable and environmentally friendly options. Its 10/20 composition makes it great for high compression applications all the way down to low flange pressures and high temperatures.
Cons:
Just like every composite in our lineup, Cork serves a purpose. In this case, a very distinct purpose. Corks strength, generally speaking, is about 1/ that of carbon fiber making it not suitable for any sort of strength conducive application. Therefore, we recommend using cork for its typical applications and being wary of using it for anything outside of its general use cases.
Typical Uses:
Cutting process Waterjet
Pros:
G10/FR-4 is widely considered a go-to material for electronics and robotics due to its specialized electrical properties, excellent dimensional stability, lightweight, fire retardancy, and chemical resistance. It is the best and most widely used electrical insulator we offer in addition to having incredibly high mechanical strength and rigidity. The material also is resistant to water absorption making it a popular choice for harsh marine environments.
Cons:
G10/FR-4 is often compared to Carbon Fiber due to its similarly woven construction and relatively similar material properties. While this is true, it’s about 25% denser and twice as weak as carbon fiber. This means that while its rigidity, strength, and weight are still exceptional, Carbon Fiber is very much in a league of its own when it comes to these attributes. The other major design consideration with G10 is that the weave differs from that of Carbon Fiber. What this means is unlike Carbon Fiber where the weave is so strong that we can’t measure a difference based on the direction of force, the strength, and rigidity of G10 are going to differ based on whether it’s lengthwise or crosswise against the weave. While that isn’t a major issue, it’s something to pay attention to if you are going to have forces in one direction that are substantially different magnitudes and how the force strains the part as you may want to manufacture your part in a specific orientation. Additionally, this material is not suited for hand machining just like Carbon Fiber so we recommend making sure your designs are completely accurate with a prototype before committing to a large G10/FR-4 order.
Typical Uses:
Cutting process: Waterjet
Pros:
Le Phenolic Linen is a high-density mixture of phenolic resin and fine weave cotton cloth that creates a composite with major insulating capabilities and remarkable creep resistance. While these make it a great choice for electrical applications, the material is also impact resistant, moisture resistant, and easily machinable. Additionally, LE Phenolic features physical toughness, abrasion, friction, and impact resistances which coupled with great fatigue strength makes it a lightweight alternative to aluminum for many applications.
Cons:
Although Le Phenolic is the second lightest composite we offer, its strength does not hold a candle to materials like G10/FR-4 or Carbon Fiber and we, therefore, do not recommend it for those sorts of use cases. It is, however, very comparable to some of the plastics we offer like Delrin so we recommend considering using it when looking for an aluminum or plastic alternative that behaves remarkably in wet or corrosive environments where aluminum or some plastics may not.
Typical Uses:
Unlike plastics, comparing costs with composites is difficult to do as each one is used for such different applications. Additionally, each price listed here is given in the thinnest variety of the respective material that we offer at the time of writing. Therefore, you may find that a suitable thickness for your application comes at a substantially different price which is something to keep in mind when comparing these materials. Generally speaking, however, the thinnest option we offer in each material is the thinnest we would recommend going for any application so just keep that in mind. At the end of the day, we don’t recommend picking a composite based on price since Cork is in no way an alternative to Carbon Fiber. We sooner recommend comparing the costs of composites, plastics, and metals you are interested in using our instant quote tool to help you better weigh your options.
One major thing to consider when choosing a composite against a plastic or metal material is the manufacturing process. ACM uses the CNC router, Cork is laser cut, and the rest of the materials are cut on a waterjet. The vast majority of the materials we offer are cut on the laser cutter so it’s important to compare the CNC guidelines to the laser cutter and waterjet guidelines. Fortunately, the waterjet and laser cut guidelines are nearly interchangeable with few discrepancies and our process handles things like kerf compensation and other complex manufacturing discrepancies. For CNC, however, the guidelines do vary quite a bit and are a little bit more demanding as far as restrictions so we recommend reading those guidelines thoroughly before committing to a material cut on the CNC route as it’s not fit for some scales and design features commonly used for certain applications.
The technical language surrounding material properties can be overwhelming, so we’ve put together this helpful cheat sheet so you know exactly what to expect from your chosen material! The specific properties for each material can be found in the “Properties” section of that material’s page. Be sure to check out our Material Min/Max chart as well to find the geometry requirements for each of our high-quality materials.
Density: How much something weighs relative to its size. This is an important attribute to consider as some of our plastics are considerably heavier than others.
Tensile Strength(Ultimate): The amount of stress that a material can withstand without breaking. This is a good indicator of how “strong” a part will be when a force pushes perpendicular to its surface.
Comprehensive (Crushing) Strength: How much force a part can withstand when being crushed. Strength like this is important to consider in scenarios where you have plates pushing against each other. A common example of this would be HDPE or UHMW used as skid plates in order to decrease the friction between two plates. If those plates don’t have high comprehensive strength, the part may crack from the force of the plates it’s separating.
Flexural Strength: How strong a part is right before it breaks. If you are designing a plate that is intended to bend this is an important attribute to consider as it’s a good indicator of how much integrity the part will retain as it’s being bent.
Shear Modulus: The material’s ability to resist small deformations over time. This is not in relation to bending but rather just the ability of the material to hold its form over time.
Impact Strength (Notched Izod): A measure of how much impact a material can withstand on one single pressure point. This sort of attribute is often looked at for things that will receive impact from fast-moving debris or will frequently receive force from one single point. A good example of this would be a rock flying at a windshield or window.
Rockwell Hardness: Simply the hardness of the plastic. The higher the number, the harder the plastic is. A harder plastic will be less prone to scratches and dents but also tends to be more rigid and more prone to shattering.
Elongation at Break: How much the material stretches when being bent to its breaking point in comparison to its original length. There is no good or bad number when it comes to elongation at break, it’s solely dependent on your application. If you have an application where you’d want the material to stretch rather than break, you want a higher elongation while if rigidity and the part holding its form is more important you want a lower percentage.
Elastic Modulus: Measure of a material’s elasticity meaning its ability to be deformed and return to its original state. Think of a rubber band and how it’ll stretch and return to its original size and shape until it eventually breaks. The higher the Elastic Modulus, the longer before it breaks.
Thermal Conductivity: The ability of a material to transfer heat from one side of your part to another. The higher the thermal conductivity, the more efficiently/quickly your part will be able to transfer heat.
Melting Point: When it comes to plastics, this is the same as decomposition temperature. Just like an ice cube turning into water, this is the temperature at which the material will either melt into a liquid or separate into multiple different liquids/materials. Simply put, the material will no longer be in its original state at and beyond this temperature.
Fatigue Strength: The most amount of stress that a material can withstand for a given number of cycles without breaking. The higher the strength, the more stress it can endure over time.
Flexural Modulus: The tendency of a material to bend. The higher the Flexural Modulus, the more the material will bend to withstand a force rather than strain statically.
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Electrical Resistivity: How strongly a material will resist an electrical current.
Maximum Temp (Mechanical): A maximum operating temperature. If you make a geared mechanism, for example, this is the maximum temperature where those pieces will hold their form and function correctly.
Vicat Softening Temperature: The determined softening point of a material that has no definite melting point. For plastics that decompose, this is the temperature where the material will start to deform.
Tensile Strength (Yield): The stress a material can withstand without permanent deformation. While Ultimate Tensile Strength specifies a breaking point, Yield represents a point where the material will be bent/deformed to a point where it won’t return to its original dimensions.
Dielectric Strength (V/mil) 1/8″: The maximum electric field that an insulating material, the plastic, in this case, can withstand.
Continuous Service Temp (Operating), °F : The maximum temperature in the air at which a material can withstand and maintain 50% of its strength.
Shear Strength: This refers to a material’s strength against a structural failure caused by a shear load which is a force applied tangent to the surface of your part.
Yield Tensile Elongation: How much a material will stretch under tension. This refers to the amount a material can stretch before permanent deformation.
Coefficient of Friction: In basic terms how slippery a material is. A common reason to use plastic is because of its relatively low coefficient of friction, especially when looking at materials like UHMW which is used primarily for this reason.
Heat Deflection Temp: Measure of a material’s resistance to a change in its shape under a given force at an elevated temperature. If I heat up my part and try to bend it, for example, this is a measure of how well the part will withstand that force in comparison to how it would in normal operating conditions.
Manufacturing methods of composite materials vary widely. The key materials that are most commonly described as composites are glass, carbon, and Kevlar® fibers, bonded with resins. In the case of carbon fiber, the strands are pre-impregnated with a heat-activated polyester, vinyl ester, polyurethane, or epoxy resin (prepreg). The flexible sheets of woven fabric (roving) are laid up onto/into a mold and put under pressure. They are then heated to activate the resin which first liquifies, wetting all fibers, then curing to a tough, rigid result.
The pressure can be applied by tooling that closes and presses the fibers. Vacuum bagging can also apply pressure when a vacuum is applied to “pull” the shape into place. A third method employs an elastic pressure bladder that uses air pressure to “push” the shape into place. The end result, after the resin is cured, is a finished part with a shape that follows a mold faithfully, with little or no shrinkage, and a rigid, tough material that exploits the two components’ best properties. Similar methods are used with glass and Kevlar® reinforcers. The completed structure is then cured at room temperature or at a slightly elevated level and then released from the mold as a finished part or product.
Polymer composites and nanocomposites are very similar in their nature. They require other processes than the more widely recognized composites of carbon fiber and GRP (glass-reinforced plastic). Whether the end result material is a nanocomposite or a macro composite depends only on the scale of the additive—macro strands or nanomaterials. In both cases, the manufacturing method is essentially identical. The reinforcer material is considered an additive and is premixed with the polymer when the pellets are first manufactured. Molded parts have evenly distributed reinforcers throughout.
Properties of composites are as diverse as the range of materials that fall within this broad classification. Under ideal conditions, the resultant properties of the composite are:
Composites are often made with a rigid matrix of epoxy resin or a less rigid but still stiff matrix of a thermoplastic polymer. This component generally lends the below primary chemical properties to the resulting material:
Some common themes in the physical properties of composites can be generalized, including:
Plastic components are generally made from a single polymer injection, or sometimes a two-stage process that overmolds rubber onto a part for specific applications such as grip and seal. They are relatively easy to manufacture, generally involving a single-stage operation. Composites, on the other hand, are always two or more co-processed materials, achieving better properties than the individual components can deliver. They are also intrinsically more complex to manufacture. They generally require manual lay-up processes and tend to be much more expensive in labor terms than simple, automatable molding operation outputs. Composites are generally intrinsically stronger than equivalent plastic parts by a large factor. This allows composite parts to deliver higher strength and reduced weight, compared with a similar plastic component.
Plastic parts are, in most regards, shape, and size unlimited. Composite parts are rarely used for very small components but can be very large, but they are quite restricted in the complexity of shapes and fine detail. Broadly, plastics are used for low-cost, high-volume applications, whereas composites are considerably more costly and are used for high-value and lower-volume tasks.
The range of composites employed in manufacture/construction is extensive, but they fall into these broad categories. These are listed below:
Nanocomposites are both man-made and naturally occurring. The reinforcer is generally a nanomaterial such as carbon nanotubes or graphene added to a polymer matrix, or silicon nanoparticles added to steel to induce fine crystal growth. In some applications, calcium carbonate or talc can also be effective in making polymers stiffer and stronger.
Typical nanocomposites use the nanomaterial additive to add strength, stiffness, and other properties such as electrical or thermal conductivity to the polymer matrix. Naturally occurring nanocomposite examples are bone and shell. Nanomaterials represent significant health risks in some cases, so manufacture of these materials can be challenging.
MMCs use a metal matrix like aluminum or magnesium and a high-strength fiber reinforcer in particle or whisker form. Reinforcers are generally carbon fiber or silicon carbide particles. This develops unique properties that go beyond the basic metal component’s limits, including: increased strength and stiffness, elevated temperature resistance before the onset of weakening, improved wear resistance, and reduced coefficient of thermal expansion.
MMCs are used in aerospace industries and extreme automotive uses, delivering high strength and low weight. They are also used in electronics, medical devices, and sporting goods. The processing of MMCs is more challenging than most other classes of composites, as high temperatures and the difficulties of uniform reinforcer distribution are challenging.
PMCs are the most prevalent and easily understood forms of composite materials. This term encompasses the hand lay-up of carbon fiber and glass fiber fabrics and the manual, injected, or pre-impregnated epoxies and polyester resins that form the matrix. These materials offer various benefits including: high stiffness and strength (compared with the part weight), great thermal, chemical, and mechanical resilience, and abrasion resistance. On the other hand, PMC requires highly skilled labor, resulting in higher costs, though these are often not excessive for applications that need a high-strength outcome.
PMCs are widely used in aerospace, automotive, marine, and sporting goods, benefitting from light weight, high strength, and stiffness. Production of PMCs involves assembly methods such as hand lay-up and filament winding, which can be slow. Precise control over the curing process is needed, to achieve ideal material properties.
GFRPs are a subset of polymer matrix composites, specific to epoxy and polyester bonded glass fiber materials. The glass fiber can be in chopped strands, lending a degree of anisotropic strength to structures by the mixed orientation of the fibers. The reinforcer can also comprise chopped strand roving (or fabric), making a more orderly process but less well suited to bulk components as fibers are all laid in one plane. Woven roving improves the quality of lay-up and can offer greater strength, at a price.
Hybrid composites are those in which two or more different reinforcing fibers are integrated into the final material. This could be a combination of glass and carbon fiber in a lay-up—for enhanced impact resistance or cosmetic reasons. It is common to use titanium mesh or strands in the manufacture of racquets for ball sports, to improve tensile and bending performance. These materials can be challenging, as compatibility issues can affect the behavior of the material—for example, one fiber may bond better to the matrix than the other. Considerable testing is required to confirm the value or feasibility of the hybrid matrix. They have the same applications as PMCs, but the higher cost restricts their use.
CMCs consist of a ceramic matrix and reinforcing fibers. A ceramic matrix provides extreme temperature and corrosion resistance and excellent wear properties. But ceramics are generally brittle when unreinforced. The addition of silicon carbide, alumina, or carbon fibers can counter the brittleness to make a more serviceable material.
CMCs are used to make gas turbine blades, specialist rocket/aerospace components, and heat exchangers. CMCs are very costly and they remain quite brittle, which limits their use. However, this is a field of intense research, and properties are improving.
There is an increasing trend toward using natural fibers in composite manufacture, to reduce the environmental impact of materials use. Natural fibers such as jute, flax, cotton, and wood are used in a variety of ways. Automotive interior panels are commonly made from resin-bonded natural fibers which are compression molded to shape and then upholstered in plastics or leather for final surfacing. Wood fibers are added to polymers for FDM/FFF rapid prototyping filaments, to improve strength and produce a wood effect. Skateboard decks make extensive use of natural fiber reinforcement, generally in a polyester resin matrix.
CFRPs are another subset of polymer matrix composites, specific to epoxy and polyester-bonded carbon fibers. For hand lay-up purposes, carbon fiber is generally used as woven roving, with a range of weave patterns used for various types of loading and stress distribution. The fibers are pre-impregnated with thermally activated resins, so the flexible cloth is laid-up and then compressed and baked to liquify and then cure the resin to create a rigid, tough result. Carbon fiber can also be pultruded with a range of polymers, to make continuous lengths of CFRP in complex sections.
AFRPs are another subset of polymer matrix composites that employ aramid as the reinforcer. Aramid fiber composites are used in the highest-impact applications. The aramid is generally used as woven fabrics that are pre-impregnated with appropriate epoxy and polyester resins, to be processed as per carbon/glass fiber. Another aramid reinforced composite is the paper/aramid honeycomb material used in low-profile flooring panels in aviation—layered with aluminum sheets and epoxy bonded, this is a typical high-value hybrid composite.
FGCs are essentially a subset of any type of composite. These are composite materials in which the constituent parts can be modified in the application or type through the structure to tune performance. A gradual transition in properties is used to avoid stress concentrations at sudden changes. The functional grading can be: as simple as adding or altering fiber content at elevated stress points; changes in weave pattern in roving to alter load distribution; or progressive hybridization for impact resilience in regions.
FGCs are used to make lighter and more resilient aircraft and spacecraft components, such as turbine blades and rocket nozzles. Biomedical devices/implants can have varied properties regionalized according to desired tissue interactions.
A range of additive materials is integrated into various polymer 3D printing materials for FDM/FFF, SLS, and other systems. The resultant materials offer enhancement of properties such as tensile strength, bending strength, hardness/abrasion resistance, etc. Examples of 3D printable composites are
Fiber and metal additives in 3D printing materials offer some potential advantages. These are listed below:
Some 3D printing processes use a form of functional grading, by co-printing rigid and elastomeric materials in the same parts, allowing properties to be varied through a build.
There are challenges in using composites in some 3D printing processes, as listed below:
There is ongoing research into ductile magnesium matrix materials with titanium reinforcement. There is also ongoing development of metal-organic framework (MOF) polymer hybrids based on poly(urethane urea) which are reported as highly ductile. Ductility is not a common property in composites, as they tend to be a merger of a rigid, often brittle matrix and a flexible and elastic reinforcer. A prime example of this is ferroconcrete, which has virtually no ductility.
Ceramics are intrinsically brittle, and ceramic composites only marginally reduce this tendency. Ceramic turbine blades have great thermal performance but rarely exhibit good impact resilience. For more information, see our guide on Brittleness.
There are hundreds of composite materials in daily use. These are some examples:
Listed below are some applications of composite materials:
The aerospace sector is always looking for higher strength and lower weight. The ability to directly manufacture parts with carbon fiber or even have continuous-strand fibers built-in offers opportunities to achieve remarkable strength levels in low-volume parts of unlimited complexity.
This is an experimental field that is not yet widely developed for making airworthy or certified manufactured parts—but this goal gets closer all the time.
No passenger-carrying aircraft will get an airworthiness certificate if built from or using 3D-printed parts in any flight-related function. This is irrespective of the materials being composite. In drones/UAVs however, extensive use is made of such parts in development and flight testing. As a rule, serviceability issues will rule such parts out from mass production.
This article presented composite materials and explained what they are, and discusssed its types, properties, and applications. To learn more about composite materials, contact a Xometry representative.
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