Question 1

For which components is CFRP particularly suitable?

Accepted Answer

Carbon fiber reinforced plastics are particularly suitable for components where high mechanical demands are required with minimal weight. Wherever high strength, stiffness, and fatigue resistance must be combined with the lowest possible weight, CFRP is the optimal choice.

Typical component applications:

High-dynamic components: Robot arms, tool holders, or spindles with low mass inertia for precise, fast movements
Structural components: Load-bearing elements in aerospace or in mechanical engineering with extreme load requirements
Precision parts: Components with tight tolerances and high dimensional stability over wide temperature ranges
Vibration-sensitive applications: Components that reduce vibrations and increase precision through their damping properties
Lightweight structures: Chassis elements, body parts, or housings for mobile applications

The crucial point is that carbon fiber reinforced plastics at BIONTEC can be specifically designed for load cases. Thanks to the load-path-optimized fiber architecture, material is placed exactly where it is needed, while weight is saved in less stressed areas.

Question 2

In which industries is CFRP used?

Accepted Answer

Carbon fiber reinforced plastics are used wherever extreme performance requirements are met with minimal weight. The range extends from high-performance applications in aerospace to precision components in metrology.

Typical applications by industry:

Aerospace: Weight reduction while maintaining high structural integrity and maximum efficiency (modern commercial aircraft consist of more than 50% composites)
Medical Technology: Lightweight, precise, and partially radiolucent components for medical devices and assistive equipment
Metrology: Dimensionally stable components with minimal thermal expansion for highly accurate measurement systems
Mechanical Engineering: High-dynamic components such as tool carriers or gripper systems with low mass inertia
Drones: Lightweight and stiff structures that enable longer flight times, higher payload capacities, and improved flight performance
Robotics & Exoskeletons: Weight-optimized structural and motion components for energy-efficient and ergonomic systems
Sports & Leisure: High-performance products such as bicycles, tennis rackets, and skis

Wherever the strength-to-weight ratio is a critical factor, fiber-reinforced plastics are the material of choice.

Question 3

Is carbon fiber reinforced plastic stronger than metal?

Accepted Answer

Carbon fiber reinforced plastics are not generally stronger than metal, but their specific strength-to-weight ratio is significantly better. This means: For the same weight, carbon fiber reinforced plastics achieve higher stiffness, or for the same strength, a lower weight. Compared to steel, up to 60 percent weight can be saved depending on the application.

The decisive advantage lies in anisotropy: While metals are isotropic and their properties are uniform in all directions, carbon fiber reinforced plastics can be specifically designed for load cases. Precise fiber orientation places strength exactly where it is needed. In highly dynamic applications with billions of load cycles, CFRP also demonstrates significantly better fatigue strength than aluminum.

Additionally, carbon fiber reinforced plastics impress with other properties that go beyond mere strength: higher stiffness, better damping, lower thermal expansion, and radiation transparency. The question is therefore not so much whether CFRP is stronger, but rather: For which application are carbon fiber reinforced plastics the better choice?

Question 4

What is the difference between CFRP and GFRP?

Accepted Answer

The main difference between carbon fiber reinforced plastics (CFRP) and glass fiber reinforced plastics (GFRP) lies in the reinforcing fibers used and the resulting mechanical properties. While GFRP consists of glass fibers, CFRP is made of carbon fibers, which are significantly stiffer and lighter.

Carbon Fiber Reinforced Plastics (CFRP):

Highest stiffness at lowest weight
Carbon fibers with stiffness up to 900 GPa
Excellent fatigue strength and vibration damping
Very low to no thermal expansion
For high-performance applications with maximum performance requirements

Glass Fiber Reinforced Plastics (GFRP):

Proven fiber type for diverse applications
More economical option for less critical load cases
Good mechanical properties at moderate weight
High radiation transparency

The choice between CFRP and GFRP depends on the requirements profile: If maximum performance, minimal weight, or highest stiffness are required, carbon fiber reinforced plastics are the first choice. For applications with less extreme demands, GFRP can be a more economical alternative.

Question 5

Is the use of carbon fiber reinforced plastics economically viable?

Accepted Answer

The use of carbon fiber reinforced plastics is economically beneficial whenever their advantages create direct added value for the application. While material costs can sometimes be higher than with conventional materials, the overall assessment often presents a positive picture.

Economic Advantages of Carbon Fiber Reinforced Plastics:

Weight Reduction: Up to 40 percent less weight leads to lower energy consumption, longer ranges, and better performance
Longer Lifespan: Excellent fatigue strength reduces maintenance costs and downtime
Functional Integration: Complex components can be manufactured as a single part, reducing assembly costs and joint points
Scalable Manufacturing: With Tailored Fiber Placement and Resin Transfer Molding, serial production can be efficiently implemented

Economic viability strongly depends on the application. In aviation, high-performance sports, or with highly dynamic machines with high cycle rates, the investment quickly pays for itself. At BIONTEC, we work with our customers to analyze whether carbon fiber reinforced plastics are the optimal solution for their specific application, and we develop economically sound composite solutions.

Question 6

Is carbon fiber reinforced plastic recyclable?

Accepted Answer

CFRP can generally be recycled. However, recycling thermoset matrix systems is more technically challenging than recycling thermoplastic matrices. The composites industry is actively developing circular solutions to further reduce the environmental footprint of carbon fiber-reinforced plastics.

Recycling options for CFRP with a thermoset matrix:

More complex recycling due to irreversible chemical cross-linking
Pyrolytic processes for thermal decomposition of the matrix and fiber recovery
Chemical recycling (solvolysis) for obtaining high-quality secondary fibers

Recycling options for CFRP with a thermoplastic matrix:

Mechanical recycling possible
Matrix system can be melted by heating
Granulation and reuse as filler or in less stressed structures possible

TFP in Medical Technology: When Fiber Architecture Determines Implant Performance

Carbon Fiber Reinforced Plastics (CFRP)

Advantages of Carbon Fiber Reinforced Plastics

Material Properties and Differences

Manufacturing of CFRP Parts

Tailored Fiber Placement (TFP)

Preforming

Resin Transfer Molding (RTM)