How Our Carbon Fiber Tubes Are Made
Understanding the manufacturing process helps you make better decisions when specifying carbon fiber tubes. Here is a step-by-step look at how we produce tubes at WHABEST Composite Solutions.
Step 1: Material Preparation
We start with genuine Toray T300 carbon fiber prepreg — carbon fabric pre-impregnated with epoxy resin at a controlled 40-42% resin content. The prepreg is stored in a freezer at -18°C to prevent premature curing, then thawed to room temperature before production. Our CNC cutting table precisely cuts the fabric plies to the required dimensions.
Step 2: Molding
Depending on the tube specification, we select the optimal manufacturing process:
- Roll Wrapping: Prepreg plies are wrapped around a precision-ground steel mandrel. Shrink tape is applied to consolidate the layers, and the assembly is cured in an industrial oven at 130-160°C for 60-90 minutes.
- Compression Molding: Prepreg layers are placed in a heated mold cavity. Hydraulic pressure compresses the material while heat cures the resin. Produces dense, void-free tubes with excellent dimensional accuracy.
- Filament Winding: Continuous carbon fiber tows are precisely wound around a rotating mandrel at controlled angles. The resin cures as the mandrel rotates under heat.
Step 3: Curing
Controlled temperature ramping and hold times are critical for proper resin curing. Our programmable ovens ensure consistent thermal profiles across every production batch, resulting in uniform mechanical properties.
Step 4: Demolding
After cooling, the tube is extracted from the mandrel or mold. For roll-wrapped tubes, the shrink tape is removed and the mandrel is extracted using precision pullers. Mandrels are inspected for wear and reused — our extensive mandrel inventory means we always have the right size ready.
Step 5: CNC Machining
Once demolded, tubes move to our CNC machining center for: precision length cutting to ±0.5mm tolerance, end facing and chamfering, drilling and slotting for mounting holes, threaded end machining (internal and external threads), and surface preparation for bonding or painting.
Step 6: Surface Finishing
Depending on your requirements, we offer: matte finish (light sanding for a satin appearance), glossy clear coat (UV-resistant for outdoor applications), painted finish (any RAL color), and textured or metallic surface treatments.
Step 7: Quality Inspection
Every tube is inspected before shipment: dimensional check with calibrated tools, visual inspection for surface defects, and mechanical testing (per batch). Certificates of Analysis are available for production orders.
Step 8: Packaging & Shipping
Tubes are individually wrapped, bundled with protective spacers, and packed in reinforced cartons or wooden crates for international shipping. We export to customers in over 30 countries.
Quality You Can Trust
Our complete in-house process — from material to finished product — means every tube we ship has been handled by our team at every stage. No subcontractors, no supply chain gaps, no quality surprises. Contact us to discuss your requirements.