URBAN AUTOMOTIVE’S IN-HOUSE CARBON PRODUCTION
APRIL 26TH - 2024
Our mission at Urban Automotive is to offer the highest quality carbon fiber on the market. Take an inside look behind the curtain at our UK carbon fiber development and manufacturing process in the YouTube episode below.
Urban components are completed to the same exacting structural and visual standards as found on high-end OEM and motorsport applications alike, using materials manufactured from both Italy and the UK.
The process begins with producing a high-resolution 3D scan using state of the art equipment with industry-leading precision (from 0.03mm). The purpose of digitally capturing the surfaces of an entire vehicle in standard form is to ensure we create an incredibly accurate foundation to begin our design process from. This process is also used for part surface inspection enabling the comparison of data to an existing CAD master model (or pattern) which allows us to quickly see deviations over the object or direct us to inspect specific points. Essentially, this all leads to ensuring our aftermarket part fits the vehicle to a standard that surpasses the standards met by OEM. Important pickup points and the capturing of specific part data 'off vehicle' are key areas of importance during this stage.
Once 3D data is 'surfaced' into CAD software, our design team work in unison with initial vehicle design renderings, capturing and modeling our established and renowned Urban design roots. Often considered 'OEM Plus' Urban delivers a well-balanced ability to tastefully enhance the aesthetics of the chosen project vehicle. The final design requires further CAD orientated expertise to be invested in order to become a viable and practical shape to mill on a 5-axis machine. This takes a further 80-100 hours plus machining time. We use a variety of epoxy-based materials combined with accurate processes to create the 'master pattern' (or male plug). Multiple layers of carbon fiber are then hand laid over the patterns, capturing all of the surface detail and forming a production, female mould. Depending on size and complexity, carbon fiber and epoxy resin moulds will sustain the ability to produce circa 500 x components. Where larger volumes are required, moulds are duplicated or replaced by repeating the tooling process.
One Urban Range Rover body styling conversion consumed approximately 300 hours of design time, before presentation for final sign off.
Without compromise, our approach to composites is executed with the highest level of manufacturing integrity there is and something the Urban brand has become synonymous with since our inception. Our highly skilled team hand lay, pre-impregnated (with resin) layers of carbon fiber material into the mould, consolidated inside a vacuum bag and then cured inside the autoclave. The intricate, aesthetic geometry of the mould is captured by the carbon fiber materials being held under atmospheric pressure at 120 degrees for 2.5 hours. Each component is removed from the mould and then hand trimmed to detail and assembled.
An Urban Range Rover SVR carbon fiber rear bumper assembly is made up of 76 individual pre-cut pieces totaling 6m of material, taking 15 hours to laminate, remove from mould and trim in order to meet our stringent internal QC process, before finally being handed over to our internal paint facility.
We currently manufacture using 2 x autoclaves (high-pressure ovens) measuring 1.35m x 3.5m and 1.45m x 5.5m, with a collective 30 x vacuum points and operating pressures of 90psi and capable of 150 degrees C. As a true measure of our design and composite manufacturing success, Urban has already won contractual, market-leading tenders from concept right through to end vehicle builds.
Pre-impregnated (with resin) layers of carbon fiber material are set into the mould, consolidated inside a vacuum bag and then cured inside the autoclave.
Not all of our white label programs are automotive-based, we have the ability to deliver an end to end service across a multitude of industries and markets. We look forward to being considered for any of your design and manufacturing projects and can present cost-effective and time-sensitive solutions for your business and brand.
