Custom Carbon Fiber Parts

HRC designs and manufactures custom carbon fiber parts to your drawing or to your weight and cost target, from a single prototype to serial production of thousands of parts a year. We work for OEMs, tier suppliers and industrial companies in automotive, aerospace, eVTOL, robotics and energy, with engineering teams in Europe and China and production plants in Changshu, China.

What custom carbon fiber parts does HRC make?

Any structural, semi-structural or visible component where weight, stiffness or fatigue life matters:

• Vehicle body and aero parts: hoods, doors, roofs, fenders, spoilers and trim panels for automotive OEMs.
• Structural parts: monocoques, floor reinforcements, battery enclosures, brackets and crash-relevant components.
• Aircraft and eVTOL parts: fuselage sections, wings, control surfaces, propulsion parts and cabin interiors for aerospace programmes.
• Machine and robot components: robot arms, beams, supporting structures and housings.
• Tubes, profiles and vessels: pultruded profiles and filament-wound tubes and pressure vessels.
• Recycled carbon fiber parts: components molded from our own rCF pellets, non-wovens and felts.

How does a custom carbon fiber part project work?

1. Brief and feasibility. Send a drawing, a 3D model or the metal part you want to replace, together with loads, annual volume and target cost. Our engineers reply with a feasibility assessment and a first cost estimate.
2. Design and material selection. Layup design, finite element analysis for stiffness, crash, fatigue and NVH, material cards from our own test lab, and a process recommendation from the design and engineering team.
3. Tooling and prototyping. Molds, master models, jigs and fixtures from our tooling and prototyping teams in Vicenza and Changshu; prototypes by autoclave, RTM or PCM, tested under real conditions.
4. Serial production. HP-RTM, C-SMC, PCM, wet compression molding, injection molding, autoclave, pultrusion or filament winding, chosen for the geometry and the volume, in our carbon fiber mass production plants.
5. Finishing and delivery. Five-axis CNC machining, bonding, painting, assembly and inspection in post-processing, under APQP, FMEA and SPC.

Which process fits your part and volume?

• Prototypes and small series: autoclave-cured prepreg or RTM, with low tooling cost and the highest laminate quality.
• Medium series: PCM, wet compression molding or C-SMC, where molding cycles of 5 to 10 minutes keep the cost per part down.
• High volume: HP-RTM, C-SMC and injection molding, with thermoplastic cycles under 300 seconds, for programmes of tens of thousands of parts a year.

Why choose HRC for custom carbon fiber manufacturing?

• One partner from design to recycling, so nothing is lost between an engineering office and a job shop.
• Certified to IATF 16949:2016 for automotive, AS9100D and Nadcap for aerospace, DIN 6701 for adhesive bonding and ISO 14001:2015 for environmental management.
• About 2,000 employees, a 30,000 square metre automotive plant and a 20,000 square metre aerospace plant, and 10 years of serial production for OEMs.
• Engineering and business development teams in Barcelona, Hamburg, West Sussex and Vicenza, close to European customers.
• A kiloton-scale carbon fiber recycling line, so production waste and end-of-life parts stay in a closed loop.

Frequently asked questions

Is there a minimum order quantity for custom carbon fiber parts?

There is no fixed minimum. Prototypes and small series run on autoclave or RTM, and the cost per part falls as the volume grows and faster processes become possible. Send your expected annual volume and we quote the right process.

Can HRC replace an aluminium or steel part with carbon fiber?

Yes. Metal-to-composite conversion is a typical brief. We start from the load cases of the existing part and deliver a lighter design with the same or better stiffness; weight savings of 30 to 50 percent are realistic.

How long does a custom carbon fiber part take?

It depends on the part size, the process and the tooling. Prototype parts follow the tooling, and serial production follows validation and first article inspection. You receive a schedule together with the quote.

Do you make one-off parts for private customers?

No. HRC works with OEMs, tier suppliers and industrial companies on development and production projects. We do not sell single aftermarket parts.

How do I get a quote?

Send the drawing or model, the material specification if you have one, and the annual volume through the contact page. An engineer replies with a feasibility assessment and a cost estimate.