If you are going to process a carbon fiber part, the optimum approach is to have a mold machined from a very expensive Invar, a metal alloy that has a similar coefficient of thermal expansion (CTE) of carbon fiber – that is to say that they expand at the same rate when heated. Steel is a cheaper option, and aluminum is less costly still, but must be sized to accommodate a vastly difference CTE.
If you are a startup, ALL of the above options cost too much!
3D printing is a very cost effective option, but the thermoplastics created that process are weak, and the processing window is limited in size.
Our work-around is mating the old with the new. This is the master pattern for the Series 1 Chair, our proof-of-concept design to validate the VARTIM process that we will use to become the IKEA of carbon fiber furniture.
In this case, we 3D printed each plane of the pattern. Then we mated each plane. From there we will VARTM the mold, and then VARTM the chair. Seems a lot of work, but saves a lot of money!
But the end result will be a beautiful and sexy carbon fiber chair embedded with and exotic hardwood veneer that will dazzle the world!
