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Carbon Fibre 3D Printing
Advanced Manufacturing

Advanced manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, etc.

Experienced Engineers


Team of expert engineers with more than 15 years of experience.

On Time Project Delivery

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation


Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

ISO 9001 : 2015

ISO 9001-2015 certified


Committed to consistently provide products and services that meet customer and regulatory requirements and to demonstrate continuous improvement.

Carbon Fibre

Being a pioneer in digital manufacturing, Zeal 3D revolutionises the industry with cutting-edge Carbon Fibre 3D Printing services. Our state-of-the-art process ensures superior strength, rigidity, heat resistance, and durability, surpassing conventional thermoplastics like PLA or ABS. Elevate your projects with Zeal 3D's specialised expertise, providing top-notch components for tooling, prosthetics, bicycles, automotive parts, and beyond.

With the synergy of 3D printing technology and cutting-edge composite techniques, carbon fibre is no longer confined to traditional applications. Zeal 3D invites you to explore a universe where innovation meets precision, unlocking the untapped potential of carbon fibre 3D printing for a myriad of groundbreaking applications.

Carbon Fibre

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Carbon fibre 3d printing

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What is Carbon fibre 3d printing?

Carbon fibre 3D printing stands at the forefront of cutting-edge additive manufacturing. It seamlessly blends traditional 3D printing methods with the incorporation of carbon fibre reinforcement. In this technique, carbon fibre strands are woven into the printing material, typically thermoplastics like nylon or ABS. The result is a composite material boasting superior strength, stiffness, and a feather-light feel. The infusion of carbon fibre significantly amps up the mechanical prowess of printed objects, making them not just durable but perfect for demanding applications in industries like aerospace, automotive, and engineering.

Direct Carbon Fibre 3D Printing

Ever heard of Direct carbon fibre 3D printing? It's this cool process where carbon fibres get mixed right into the material as the 3D printer does its thing. Usually, they use thermoplastic matrices like nylon or ABS, throw in some short carbon fibre strands, and let the magic happen. The 3D printer melts this combo material and builds up layers, creating objects that are not just cool but also super strong and stiff. It's known for being simple, speedy, and can make tough parts perfect for all sorts of uses, from aerospace to cars and industrial stuff.

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Chopped Carbon Fibre 3D Printing

Now, let's talk about Chopped carbon fibre 3D printing . Picture this: short bits of carbon fibre mixed with a polymer matrix in filament form. These filaments go into a 3D printer, where they melt and stack up layer by layer to create some seriously cool composite parts. The chopped carbon fibre gives the material a boost, making it stronger and more rigid. The best part? It's a hit because it plays nice with existing 3D printing systems. This method is like the superhero of making parts – stronger and lighter, perfect for everyday items and heavy-duty industrial gear.

Continuous Carbon Fibre 3D Printing

This one's a game-changer – they use these constant strands of carbon fibre mixed with a thermosetting resin. Unlike the other methods, the carbon fibre here runs without a break through the material, giving the whole printed object unbeatable strength. The mechanical properties are off the charts, with high tensile strength and top-notch fatigue resistance. Industries like aerospace and automotive are all over it because it makes parts that are not just light but also tough as nails. When you need peak performance, especially where safety and efficiency matter, continuous carbon fibre 3D printing is the go-to.

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Advantages Of Carbon Fibres

Impressive Strength-to-Weight Ratio

Carbon fibres are renowned for their exceptional strength and stiffness, giving them a fantastic strength-to-weight ratio. This quality makes them perfect for situations where you need materials that are both lightweight and incredibly strong, like in the aerospace and automotive industries.

Minimal Thermal Expansion

One cool thing about carbon fibres is their ability to resist thermal expansion, meaning they keep their shape and structural integrity even when temperatures fluctuate. This feature comes in handy in applications where maintaining a consistent size is crucial, like in satellites and precision instruments.

Top-notch Fatigue Resistance

Carbon fibres boast excellent fatigue resistance, allowing them to endure repeated stress cycles without

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wearing down. This is particularly beneficial in scenarios where materials face dynamic loads over time, such as in sports equipment and structural components.

Customisable Mechanical Properties

What's neat about carbon fibres is that you can customise their mechanical properties to fit specific requirements. By tweaking factors like fibre orientation, weave pattern, and resin type, you can create materials with optimised performance characteristics.

Adaptability in Composite Materials

Carbon fibres are often used as reinforcements in composite materials, like carbon fibre-reinforced polymers (CFRP). These composites strike a great balance between strength, stiffness, and durability, making them invaluable in a variety of applications ranging from automobile components to athletic products.

Sturdiness and Longevity

Carbon fibres are tough cookies with a long lifespan. Their ability to resist environmental factors, fatigue, and wear makes them a go-to choice for applications where durability and reliability are key, such as in structural engineering and infrastructure.

Freedom in Design

Thanks to their malleability, carbon fibres offer a lot of design freedom. You can shape and mould them into various forms, allowing for the creation of intricate and lightweight structures that would be a challenge with traditional materials.

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Source : Freepik.com

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Blending Traditional Techniques with 3D Printing for Crafting Carbon Fibre Components

Combining traditional methods with 3D printing techniques in the creation of carbon fibre parts allows for a hybrid strategy that takes advantage of both processes' capabilities.

Wet Lay-Up

  • Process : In wet lay-up, carbon fibre fabric is manually impregnated with liquid resin and then applied layer by layer onto a mould. The resin cures over time, forming a solid composite structure.
  • Integration with 3D Printing : Combining wet lay-up with 3D printing involves printing a base structure using traditional 3D printing methods and then manually applying carbon fibre layers using the wet lay-up process. This hybrid approach allows for customisation and reinforcement in specific areas, optimising strength and weight distribution.

Prepreg Lamination

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  • Process : Prepreg involves pre-impregnating carbon fibre fabric with resin, ensuring precise resin content. The material is then cured under heat and pressure to achieve the desired mechanical properties.
  • Integration with 3D Printing : In this approach, 3D printing is used to create the base structure, and prepreg carbon fibre sheets are layered onto the printed surface. The combined use of prepreg lamination and 3D printing offers a balance between automated fabrication and the high-performance characteristics of prepreg materials.

Resin Transfer Moulding (RTM)

  • Process : RTM involves injecting liquid resin into a closed mould containing the carbon fibre reinforcement. The resin fills the mould's cavity, bonding with the fibres, and then cures to form the final composite part.
  • Integration with 3D Printing : Combining RTM with 3D printing entails creating a 3D-printed mould, which is then used in the traditional RTM process. This hybrid method allows for the efficient production of complex geometries through 3D printing while benefiting from the superior material properties achieved through the RTM process.

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Crafting Carbon Fibre Components Using 3D Printed Moulds

Creating carbon fibre components with 3D printed moulds is a clever fusion of additive manufacturing perks and the strengths of traditional carbon fibre crafting techniques. Let's walk through the process step by step:

Design and 3D Printing of Moulds:

First things first, sketch out the part you want and whip up a mould using 3D printing. This mould can get pretty fancy, accommodating intricate shapes that are a bit tricky with traditional moulds. The beauty of 3D printing? You can quickly prototype and tweak the design before hitting the production stage.

Surface Treatment:

After the 3D printer does its thing, some post-processing steps come into play. This is where we fine-tune the surface finish to make sure it's spot-on for the carbon fibre production.

Carbon Fibre Lay-Up:

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Now, the fun part. Layer up some carbon fibre fabric or prepreg sheets right into that 3D printed mould. It acts like a precision tool, shaping the carbon fibre into whatever cool form you're aiming for.

Resin Infusion or Curing:

Time to add some resin to the carbon fibre layers. You can go with methods like vacuum infusion or resin transfer moulding. Alternatively, you can let the whole shebang cure, creating a solid composite structure.

Demolding:

Once the resin has worked its magic and your composite part is looking slick, pop that mould off. Oh, and the best part? You can use the same 3D printed mould over and over for more production runs.

Post-Processing:

Last but not least, give your carbon fibre creation a great finish. Trim off any excess material and polish it up until it meets your final specs and there you have it—a cool process that blends cutting-edge 3D printing with the classic finesse of carbon fibre crafting.

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Carbon Fibre Components

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Automotive Industries with Carbon Fibre 3D Printing

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Applications Of Carbon Fibres Industries

Automotive Industries:

  • Body and Structural Components: Carbon fibres play a pivotal role in the automotive world, creating nimble and robust body panels, chassis components, and structural elements. This not only makes vehicles lighter but also boosts fuel efficiency and overall performance.
  • Interior Components: Inside the car, carbon fibre composites step up to the plate, adding a touch of strength and style to features like dashboards, seat structures, and trim pieces. It's the perfect blend of durability and aesthetics.
  • Brake Systems: Carbon-ceramic brake discs, incorporating carbon fibres, offer enhanced performance by reducing weight and improving heat dissipation.

Aviation Industries:

  • Aerospace Structures:In the vast skies of aviation, carbon fibres take centre stage in manufacturing key aircraft components, including wings, fuselage sections, and tail components. The lightweight magic of carbon fibre isn't just for show—it significantly contributes to better fuel efficiency and overall aircraft performance.

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  • Interior Components: Inside the aircraft, carbon fibre composites make their mark in components like seats and cabin structures, shedding unnecessary weight and boosting fuel efficiency. It's all about making every part count.
  • Rotor Blades: Helicopters and certain aircraft owe their impressive performance to carbon fibre composites in rotor blades. The secret? Exceptional strength and stiffness that keep them soaring through the skies.

Marine Industries:

  • Hull and Structure: Carbon fibres find their way into the marine industry, constructing sturdy hulls and structural components for boats and ships. The impressive strength-to-weight ratio isn't just for bragging rights—it significantly improves performance and fuel efficiency.
  • Masts and Rigging: Sailboats catch the wind with finesse, thanks to carbon fibre masts and rigging. Lightweight, durable, and corrosion-resistant, these components make sailing not just a journey but a statement.
  • Submersibles and Underwater Equipment: Explore the underwater wonders with confidence, as carbon fibre composites dive into the construction of submersibles, underwater vehicles, and equipment. Their resistance to corrosion and formidable strength make them the perfect companions in underwater environments.

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Why Choose Zeal 3D for Carbon Fibre 3d Printing?

One-stop solution :

At Zeal 3D, we are your one-stop solution for cutting-edge carbon fibre 3D printing solutions. Our commitment is to seamlessly meet all your 3D printing needs, providing a comprehensive range of services from conceptualisation to the final production step. With a focus on Carbon Fibre 3D Printing, we offer a precision-driven and reliable experience, ensuring that your projects benefit from the exceptional properties of carbon fibre materials.

Tailored and On-Demand Services :

Discover our affordable and top-notch carbon fibre 3D printing services, tailored to suit your unique project requirements. At Zeal 3D, we stand out in providing customised and on-demand Carbon Fibre 3D printing solutions. Our collaborative approach ensures each project is unique and perfectly aligns with your vision, resulting in one-of-a-kind, high-performance components.

Cost-Efficient :

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Our carbon fibre 3D printing services not only embrace the latest technology but are also budget-friendly. By leveraging efficient carbon fibre manufacturing processes and strategic partnerships, we offer value-driven solutions for your projects. We recognise the necessity of sticking to a budget, and our goal is to deliver quality within your financial parameters.

Quality Assurance :

Quality sits at the top of our priority list at Zeal 3D. Our rigorous quality assurance processes guarantee the precision and reliability of every 3D-printed carbon fibre component. With meticulous attention to detail and a commitment to industry standards, we consistently surpass expectations, ensuring your projects benefit from the superior strength and durability of carbon fibre.

Diverse Material Support: :

At Zeal 3D, we take pride in offering a wide array of carbon fibre materials to support various applications. Whether you're after the strength of metals or the adaptability of plastics, our carbon fibre 3D printing solutions guarantee that your products meet the highest performance and functionality standards.

On-time Delivery :

Recognising the significance of time, Zeal 3D understands the importance of on-time delivery. Our unwavering commitment to punctuality ensures that your Carbon Fibre 3D printed components are delivered within agreed-upon timelines without compromising on quality. Choose Zeal 3D for a seamless and reliable 3D printing experience!

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