What is Forged Carbon?

Forged Carbon is an advanced material that finds application in various industries due to its unique properties such as low weight, high hardness, good corrosion resistance, and appealing aesthetics, and is expected to continue to gain importance in the future.

It is a composite material made of carbon fibers and a resin matrix, produced through a complex manufacturing process.

Forged Carbon is used in aerospace, automotive industry for body and accessory parts, interior trim, and wheels, in sports equipment, and, of course, in everyday wearables and accessories, such as watches, protective cases, card holders, and many more.

What is the difference between classic and Forged Carbon?

Classic Carbon consists among other things of carbon fibers. These fibers are braided on weaving machines, giving them their well-known structured look.

Forged carbon , also known as forged composite, uses chopped carbon fibers mixed with resin as a base. This mixture can be molded into almost any shape. Because the carbon fibers are not woven here, there is no clear pattern and each Forged Carbon product is unique.

 

How is Forged Carbon made?

The chopped carbon fibers are placed in a mold together with epoxy resin, which has to be made individually for each component, and then pressed into shape under high pressure. This process is also known as "compression molding".

Source: Langzauner hydraulic press Compositesworld.com

Since this process is comparable to forging (to forge) metals, the name "Forged Carbon" came about.

There are a few other ways to make forged carbon without a compression press, such as with prefabricated mats or even laid one by one by hand.

 

What are the benefits of Forged Carbon?

In addition to the most obvious advantage from my point of view, the unique design, forged carbon is particularly suitable compared to braided 'standard' carbon when tight angles or complex three-dimensional shapes are required. Braided carbon just doesn't get pressed into the corners as well and it also takes longer to align the fiber mats layer by layer.

Given the right form (compression mold), many parts can be created in a shorter time.

Also compared to other materials commonly used in everyday items, Forged Carbon performs very well, as summarized in the following table:

 

Properties	Forged Carbon	Titan	Stainless Steel	Aluminium	Plastics	Leather
Weight(g/cm³)	1,6 - 1,8	4,5	7,9	2,7	1,0 - 2,5	0,9 - 1,4
Density (g/cm³)	1,6 - 1,8	4,5	7,9	2,7	1,0 - 2,5	0,9 - 1,4
Tensile Strength (MPa)	3.500 - 6.000	900 - 1.400	500 - 2.000	90 - 500	10 - 100	10 - 20
Compressive Strength (MPa)	500 - 900	900 - 1.400	500 - 2.000	90 - 500	20 - 100	-
Elongation at Break (%)	0,5 - 1,5	Okt 20	40 - 60	Okt 20	200 - 700	100 - 300
Corrosion Resistance	very high	very high	high	medium	low	low
Hardness (Vickers)	800 - 1.200	200 - 500	150 - 300	15 - 120	20 - 60	low
Appearance	Unique grain, deep black	Metallic shine	Metallic shine	Metallic shine	Various colors and textures	Various colors and textures

 

This data show that Forged Carbon has a similar density/weight as plastic and leather, but is lighter than common metals while having a higher tensile strength and comparable compressive strength.

In terms of elongation at break, Forged Carbon is relatively stiff, which means it can be more brittle.

The corrosion resistance of Forged Carbon is very high, making it an ideal material for applications that come into contact with liquids or salts.

In terms of hardness, Forged Carbon is relatively hard, making it more resistant to scratches and wear, and therefore also suitable for everyday carry products (EDC) such as the Forged Carbon Wallet, the Forged Carbon KeyCase, the Forged Carbon AirPods Case, the Forged Carbon iPhone 14 Case or the Forged Carbon Samsung S23 Case 

 

What are the disadvantages of Forged Carbon?

It may sound strange, but yes, Forged Carbon also has certain disadvantages compared to other materials. First and foremost, its price. It is more expensive than materials such as plastic or leather, and its processing is more difficult, which usually leads to higher production costs.

Nevertheless, it is a material that is gaining popularity among manufacturers and consumers due to its unique properties and aesthetics – despite higher prices compared to traditional carbon or other materials.

The history of Forged Carbon

In 2008, Lamborghini used forged carbon/ forged composite for the first time in a concept car, the Sesto Elemento . It was first presented to the public at the 2010 Paris Auto Show and is considered the most radical concept vehicle ever built by Lamborghini.

Source: Lamborghini Sesto Elemento

The name is intended to express the connection to the sixth element (carbon) in the periodic table, since the outer skin of the Sesto Elemento consists mainly of carbon fiber reinforced plastic.

The vehicle is a high-performance super sports car, primarily made from Forged Carbon. By using Forged Carbon, the weight of the Sesto Elemento was impressively reduced to 999 kilograms, with a power output of 570 PS. The result was an acceleration of 0 to 100 km/h in just 2.5 seconds and a top speed of over 320 km/h.

Source: Lamborghini Sesto Elemento

The Sesto Elemento was a masterpiece of engineering and technology, showcasing the possibilities that Forged Carbon brings to lightweight component construction in the automotive industry. Although the Sesto Elemento was never produced in series, it served as a precursor to later Lamborghini models such as the Huracán Performante and the Aventador SVJ, which also incorporate Forged Carbon parts in their design.

Source: Lamborghini Forged Composite

The technology was then acquired by The Outokumpu Group and renamed Forged Carbon. Since then, the material has been increasingly used in various industries, from aerospace to fashion and accessories, as its unique organic appearance makes it a coveted material for designers, artists, and individualists.