Materials: Carbon

Product design process begins in the design department in Ivančna Gorica. When we receive a new motor in our test room, we simultaneously begin developing a new exhaust system and carbon parts.

The products are designed with a computer program, which produces a 3D model (so called CAD – Computer Aided Design), in a form which is suitable for machine milling. Then a programmer, using computer software, sets milling parameters, which take a square solid material and transform it into a desired form with a good quality surface finish (so called CAM – Computer Aided Manufacturing). At the end, the polishing section also plays a crucial role, because they bring the surface of the model to a high-gloss finish. Tools for clamps and muffler sleeves do not need to be polished, because the workers see to the high quality of the outer surfaces by polishing it.

Produced tools are coated with various polishing agents as many as 10 times, which prevent adhesion and are as such prepared for mass production.

A laminate plan and cuts of individual layers are prepared for all carbon products. All materials are then cut with a computer-guided cutter, which has a cutting speed of up to 1 m/s. They are:

• separation foil,
• felt that absorbs superfluous resin,
• vacuum bag,
• carbon (in dry woven thread form),
• resin pre-impregnated resin (prepreg),
• aramid (in dry woven thread form – kevlar),
• glass fibers in dry and pre-impregnated form;

We use various technological procedures, depending on the specific nature of products, which are divided into the following groups:

• muffler supports and temperature shields are produced using a procedure (wet) in which we use dry carbon fabric and epoxy resin. The tool is produced from high-gloss aluminum, consisting of a lower (mould or matrix) and upper section (press stud or puncher). Both parts of the tool as well as the epoxy resin are pre-heated. Carbon layers are placed on the lower part of the mould and each one is impregnated with resin; at the end we press on it with the upper part of the tool and strengthen it by placing it in the furnace at a temperature of 80-120°C;
• muffler sleeves are produced using a procedure (wet) in which we coil dry carbon fabric onto a pre-heated tool made from steel or grey cast iron and impregnate it with a pre-heated high temperature-resistant resin. At the end we wrap it with a special foil and strengthen it in the furnace, first at a temperature of 130°C and later at 300°C;
• clamps, carbon caps and other accessories  are produced using a special procedure in an autoclave. In the production of clamps, we place pre-impregnated carbon fiber on a tool made from steel or gray cast iron, place a press stud and felt on it and fasten it with a special foil and sealing tape. The foil contains a valve, which is connected to a tube that sucks out air and compresses carbon layers, resulting in the draining of superfluous resin. 

The process is similar in the production of carbon caps, mudguards, masks, etc.; the only difference being that the pre-impregnated carbon fiber is placed in the negative. Separation foil and felt are placed in the mould after carbon; and the whole thing is placed in a vacuum bag with a valve, which is connected to a vacuum. Products are then placed on a shelf in an autoclave, where it is strengthened at 7 bars and 140°C.

Trimming and cutting is done manually, except in the case of carbon caps, which are inserted in special chambers and treated using a CNC device. We use various devices for drilling clamps and milling grooves. Grinding of carbon parts, which are later painted, takes place in a chamber using water pressure and an abrasive agent.

The paint area consists of a coating chamber and furnace for strengthening. The dust coating procedure that we use provides carbon products with a beautiful finish as well as resistance to UV rays and high temperatures.