Resin infusion seems to be the most advanced process reachable by hobbyists and seems relatively simple.
Big parts can be made.
For pre-infused parts, a big Oven is needed in addition which requires a lot of space and might be unsuitable for hobbyists who only want to make one or two large CF parts. The performance of resin infusion and pre infused carbon fiber is simmilar. pre infused fiber seems easier to work with. especially on tight corners or overhangs.
-> a basic setup is ~400-700$
Cost of making cf parts
the cost for cf parts is surprisingly low, given you are relatively skilled/experienced and excluding the labour cost. Most materials used are consumable, but quite simple and cheap.
Most carbon fiber mesh can be used. Usually, simmilar to cigars the outer most layer is a premium mesh with no imperfections. This is just for the visuals though.
For visual parts, twill or satin is preferred due to clean finish.
Careful with aramid fibers on the ouside mesh. They fray when sanding and are not uv stable. they discolorate over time. Many materials can be used on the outside layer including thin metal foils, meshes or printed fabrics for visuals.
Other than that, even ali express fibers seem qualitatively good for hobbyist projects.
| Weave Type | Fabric Weight (gsm) | Typical Layer Thickness (mm) | Notes |
|---|---|---|---|
| Plain Weave | 160 gsm | ~0.18 mm | Tight weave, moderate crimp |
| 200 gsm | ~0.22 mm | Common choice for shells | |
| 300 gsm | ~0.33 mm | Stronger, less flexible | |
| 400 gsm | ~0.44 mm | fewer, thicker layers | |
| Twill Weave | 200 gsm | ~0.20–0.24 mm | Slightly thinner than plain |
| 300 gsm | ~0.30–0.35 mm | Smooth visual, easier drape | |
| 400 gsm | ~0.40–0.45 mm | strength + aesthetics | |
| Unidirectional | 200 gsm | ~0.17–0.20 mm | Very flat; no cross-weave |
| 300 gsm | ~0.25–0.30 mm | strength in one direction | |
| Satin Weave | 300 gsm | ~0.30–0.35 mm | Flexible, smooth finish |
| Hybrid Weaves | Varies | Depends on component fiber mix (e.g., Kevlar + CF) |
| Thickness (mm) | Tensile Strength (MPa) | Flexural Strength (MPa) | Practical Application Description |
|---|---|---|---|
| ~0.22 mm | ~400–500 | ~600–700 | ⚠️ Cosmetic only — decals, visuals, or finish layers. |
| ~0.45 mm | ~550–650 | ~700–850 | ⚠️ Very flexible — for non-load-bearing shells, deco |
| ~0.7 mm | ~650–750 | ~800–950 | 🚧 Good skin layer for foam sandwich panels. floppy still |
| ~0.9 mm | ~700–800 | ~850–1000 | ✅ Basic structural skin — flexible but supportive. |
| ~1.1 mm | ~750–850 | ~950–1050 | ✅ For light bracketing, semi-rigid. Slight flex under load. |
| ~1.3 mm | ~800–900 | ~1000–1100 | ✅ Semi-rigid panel — works for drone parts, medium stress |
| ~1.55 mm | ~850–950 | ~1050–1150 | ✅ Reinforced skin — adds impact protection |
| ~1.8 mm | ~900–1000 | ~1100–1200 | ✅ Rigid and reliable — ideal for drone arms, large hulls |
| ~2.0 mm | ~950–1050 | ~1150–1250 | ✅ Mid-weight structural parts — base plates, or hatches. |
| ~2.2 mm | ~1000–1100 | ~1200–1300 | ✅ Structural shell — robotics, boat hulls, mounts. |
| ~2.4 mm | ~1050–1150 | ~1250–1350 | ✅ Stiff support layers — robot armor, sports gear |
| ~2.6 mm | ~1100–1200 | ~1300–1400 | ✅ Heavy-duty — mounting systems, longboards |
| ~3.0+ mm | ~1200+ | ~1400+ | 💪 High-stress parts — prefer unidirectional carbon |