The process of manufacturing carbon-fiber-reinforced polymer

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The process of producing carbon-fiber-reinforced polymer is critical in the production and assembly of the Lamborghini Urus. The Lamborghini Urus is a concept automobile designed by the Lamborghini Corporation, which specializes in the production of sports cars (Hope, 2015). To make this car a reality in 2018, when production is planned, the process of creating and upgrading the carbon-fiber-reinforced polymer must be well implemented (Masuelli, 2013).

The carbon-fiber-reinforced polymer synthesis process was chosen as the engineering/manufacturing technique for this paper. The compound is also known as carbon fiber reinforced plastic and carbon fiber reinforced thermoplastic. They are one and the same thing. Carbon-fiber-reinforced polymers are often expensive to produce but are necessary for applications where high strength to weight ratio is desired. Additionally, the carbon-fiber-reinforced polymer adds rigidity to the equation thus making it a viable candidate for the Lamborghini Urus (Lamborghini, 2015).

Carbon-fiber-reinforced polymers are comprised of a binding polymer, a composite and additives such as silica. The binding polymer often takes the form of a thermoset resin. An example of such a resin is epoxy. However, other thermoset substances such as polyester, thermoplastic polymers, vinyl ester and nylon could be used. The substance used as the composite material can contain several fibers apart from the carbon fiber. Examples of such fibers are Aramid, such as Kevlar and Twaron, ultra-high-molecular-weight polyethylene (UHMWPE), aluminum and glass fibers. When it comes to Resin, silica is often used. However, other additives such as carbon nanotubes and rubber and can be used. Graphite-reinforced polymer or graphite fiber-reinforced polymer is less commonly used as it can clash with the glass-fiber reinforced polymer (Masuelli, 2013).

From this perspective, the manufacturing of carbon-fiber-reinforced polymer is essentially te process by which these elements are combined into the final product. That is; the binding polymer, the composite and the additives. Every one of them is important in the manufacturing process. The final product is use on the Urus as the body of the vehicle. The Lamborghini Urus sports utility vehicle (USV) that is manufactured by a company that specializes in the manufacture of sports car. It is essentially a hybrid car that incorporates the elements of a personal car and those of a sports car. To understand the paradigm here, a sports car is essentially optimized for speed and robustness on the track while a sports utility vehicle is optimized for style and comfort for the occupants.

Potential Defects and their Impacts

One potential defect that may cause a deviation in the development process of the carbon-fiber-reinforced polymer is the clash of the additives. This specifically affects the graphite fiber-reinforced polymer and glass reinforced polymer. However, due to the clash, the graphite fiber-reinforced polymer is less commonly used. Secondly, there is the potential for contamination during the manufacturing process. This can leave the final product with poor integrity in terms of strengths and durability. This would be bad for the automobile driver who can incur huge losses and possible his/her life. The structural integrity of the polymer must be maintained and guaranteed for safe driving. Additionally, toxic contaminants such as carcinogens must be kept away from the site. Their accidental addition can cause ailments to the consumers and cost the company plenty of cash in recall costs and medical bills for the consumers. Thirdly, there is the possibility of defects that arises from not using the correct temperatures during the manufacturing process. To effectively melt the glass and the composites, the proper temperature must be used. The integration into the final product depends on proper melting and molding (Wanberg, 2012).

Use in Waste Minimization

Carbon-fiber-reinforced polymer contributes to waste minimization largely through its durability. By producing a high-quality carbon-fiber-reinforced polymer, the manufacturing process ensures that there is a longer turnover cycle. It takes much longer to replace a carbon fiber body. As a matter of fact, the carbon fibers bodies often last the entire lifespan of the vehicle. The manufacturing process maximizes production since it is well documented and leaves little waste. The various components used in the manufacturing process are often consumed wholly without leaving unnecessary raw materials. Last but not least, there is the aspect of using carbon in the process. This helps reduce the quantities of carbon that requires sequestration with the appropriate technologies.


The process of manufacturing carbon-fiber-reinforced polymers is a delicate process that must be done to perfection. This ensures that the components are well incorporated and the final product meets the integrity requirements in terms of the structure that is required of it. At this point, it is important to note that the Lamborghini Urus is a sports Utility vehicle and must be kept as light as possible while strong at the same time. It is this rationale that informs the use of the carbon fiber body despite its apparent prohibiting cost. The carbon-fiber-reinforced polymer is essentially a plastic and a composite one at that. This means that like similar polymers, it is non-biodegradable. As a matter of fact, it is much harder to recycle than regular non-composite plastics. It makes up for this in its durability (Stark, 2011).

Works Cited

Hope, G. (2015, December 1). Lamborghini Urus will go into production in 2018, powered by a

4.0-litre twin turbo V8. Retrieved Janury 20, 2017, from


LAMBORGHINI S.p.A. Lamborghini.

Masuelli, M. A. (2013). Introduction of Fibre-Reinforced Polymers − Polymers and Composites:

Concepts, Properties and Processes. Intech.

Stark, J. (2011). Product Lifecycle Management: 21st Century Paradigm for Product Realisation

(Decision Engineering) 2nd ed. Springer; 2nd ed. 2011 edition.

Wanberg, J. (2012). Composite Materials: Fabrication Handbook #3 (Composite Garage

Series). Wolfgang Productions.

May 10, 2023

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