CARBON SUPERCOMPOSITE ™

A Durable, Safe, and Unique Carbon Fiber Composite

BOSTONMATERIALS

A New Dimension of PerformanceBoston Materials offers composite component manufacturers

Carbon Supercomposite™, a drastically toughened carbon fiber

composite with enhanced Z-axis properties that exhibits signs

of plastic deformation before fracture.

This material-level solution is made by applying a coating

of Z-axis oriented, milled carbon fibers to standard

carbon fiber fabrics, forming a 3D prepreg with dense

interlaminar reinforcement. Boston Materials supplies Carbon

Supercomposite™ as prepregs that are compatible with

virtually all carbon fiber composite manufacturing methods.

Performance by Design Carbon Supercomposite™ was created to overcome

the shortcomings of traditional 2D composites with

a patented fiber reinforcement that delivers highly

differentiated functionality and performance.

Durability with Stiffness

This revolutionary material utilizes

advanced methods to toughen

composites without sacrificing

strength or stiffness. Milled fiber

reinforcement of the material’s

Z-axis increases toughness by 300%

and strength by 35% without any

detriment to stiffness.

Safety via Plastic Deformation

With Carbon Supercomposite™, failure

is preceded by signs of deformation

due to delamination pinning.

Unique Thermal and

Electrical Properties

Milled fibers increase the Z-axis

thermal and electrical conductivities.

This enables PAN-based carbon

fiber composites to match the

conductivity of more expensive

pitch-based alternatives.

300% Increase in Through-Thickness Thermal Conductivity

Compressive Strength

35% More Enhanced

Traditional Carbon

Fiber Compression

Compressive

Toughness

300% More Enhanced

2 Carbon Supercomposite™

How it Works: Z-Axis Milled Fiber Reinforcement

Carbon Supercomposite™ is formed by coating a standard carbon fiber fabric with milled carbon fibers. The milled

fibers are vertically oriented by using a proprietary process. These Z-axis milled fibers mechanically pin the layers

of a laminated composite together, drastically increasing the interlaminar fracture toughness. This patented

interlaminar toughening mechanism effectively distributes multi-axial loads throughout the entire composite.

Compression

The lack of toughness in

carbon fiber laminates

is exacerbated under

compression where planar

compressive forces manifest

as a combination of Mode I

and II loads. Reinforcing the

interlaminar region with Z-axis

milled fibers provides bulk

toughness of over 12 MJ/m3.

This demonstrates a 300%

enhancement over current

carbon fiber materials.

3Carbon Supercomposite™

A Better Material for Your Applications

Carbon Supercomposite™ brings new design

improvements and performance benefits to

your demanding materials applications.

Sporting Goods:

Protecting your users while elevating product performance is

the ultimate goal. Carbon Supercomposite™ is a powerful tool

that delivers a competitive edge with a new level of safety.

Oil and Gas:

Corrosive and abrasive environments make it challenging to deliver

components that resist wear over a longer lifespan. Integrating Carbon

Supercomposite™ in your products can provide a unique combination of

compressive strength and wear resistance.

Pressure Vessels:

Higher energy density requirements for Type IV and V pressure

vessels make repeatable production of durable carbon fiber

composites a concern. Carbon Supercomposite™ allows you to

simplify your designs and increase manufacturing productivity.

Marine:

Carbon Supercomposite™ withstands rolling and irregular

forces, even under constant exposure to weather conditions.

This makes it ideally suited for a wide range of marine

applications from battens and hydrofoils to fins and rudders.

Automotive:

Safety is the top priority for crash structures and battery

packs. The toughness of Carbon Supercomposite™ can

enable lightweight designs that can take a hit.

Wind Energy:

The future is trending towards super-sized wind turbine blades

to increase energy density and return on investment. Carbon

Supercomposite™ can enable this trend by simplifying the layup

process while providing tolerance to defects and damage.

Aerospace:

Durability of high-temperature, carbon composite (C-C)

components like carbon seals is a critical safety issue for

modern aircraft. Carbon Supercomposite™ can be used to

produce tougher and more shock resistant C-C materials.

Carbon Supercomposite™4

5Carbon Supercomposite™

Carbon Supercomposite™ Vs. Traditional 2D Carbon Fiber

Patented Three-Step Manufacturing Process

Carbon Supercomposite™ utilizes

an innovative, environmentally-

responsible manufacturing process

to provide new performance

benefits while keeping costs low.

STEP 1: FABRIC SELECTION

Select any crimp or non-crimp fabric.

STEP 2: Z-AXIS MILLED FIBER

Add a coating of milled carbon

fibers in vertical alignment.

STEP 3: RESIN

Apply customer preferred

resin system.

CARBON SUPERCOMPOSITE™

+ +X Y = XYZZ

3

SupercompositeTM

bending point

TRADITIONAL 2D CARBON FIBER

+ =X Y XY

3

Traditional breaking point

6 Carbon Supercomposite™

Out-of-the-Box Compatibility Means Faster Time-to-Market Carbon Supercomposite™ is compatible with all layup,

automated tape laying, and roll wrapping manufacturing

methods. Prepregs are available with standard 250°F

and 350°F cure epoxy resins; unique resins can be

produced upon request. Prepregs rolls are currently

available up to 12-inch wide and up to 50-yard lengths.

Our Applications Team will work with you to quickly

integrate Carbon Supercomposite™ into your

established designs and production processes to

decrease your technical risk and time-to-market.

Take Your Application to the Next Generation of Performance Carbon Supercomposite™ by Boston Materials offers

unique advantages and cost savings that makes you

more competitive and strengthens your bottom line. To

learn more about this technological advance in carbon

fiber and how we can help you incorporate it into your

durable, safer, and unique products – contact us.

Carbon Supercomposite™ 7

Boston Materials 23 Crosby Dr, Bedford, MA 01730

P: (617)-227-2422 E: info@bostonmaterials.co W: bostonmaterials.co

©2019 Boston Materials, Inc.

BOSTONMATERIALS