CFRTP (Carbon Fiber Reinforced Thermoplastic) is widely recognized as a next-generation composite material due to its high stiffness and lightweight properties. Its application in large-scale components provides significant value in transportation equipment, industrial machinery, and structural applications. However, stable manufacturing of large CFRTP parts requires advanced processing equipment and a robust quality assurance system.

Kawamura Kikai Co., Ltd. is equipped with facilities capable of molding components up to 500 × 500 mm and has established an integrated system from prototyping to evaluation. The following outlines the key features and support framework for large-component molding.

【Large-Scale Molding Equipment】
Kawamura Kikai Co., Ltd. operates press systems with a maximum clamping force of 200 tons and molding temperatures up to approximately 400 °C. The maximum mold size is 1200 × 1500 mm, enabling production of components up to approximately 500 × 500 mm. This capability supports both prototyping and mass production of not only small parts but also large panels and covers.

【Molding Materials and Intermediate Materials】
Supported resins include common thermoplastics such as PP, PA6, and PA66, as well as bio-based resins including PLA and PA11. Available intermediate materials include prepreg, nonwoven fabric, chopped fiber, and UD tape, enabling optimal material selection based on design requirements and cost considerations, even for large components. By optimizing resin systems and fiber orientation, high stiffness can be maintained while achieving weight reduction in large parts.

【Molding Conditions and Verification】
For large components, cooling behavior and pressure uniformity directly affect product quality. Kawamura Kikai Co., Ltd. utilizes both heat-and-cool molding and cold press processes, optimizing parameters according to part geometry, surface requirements, and production volume. Since cooling time varies with thickness and rib structures, precise condition control is essential. Process parameters—temperature, pressure, and cooling—are first validated using an A4-size flat plate mold, then applied to the final product geometry.

【Inspection and Quality Assurance】
Post-molding quality verification is conducted using both in-house inspection systems and external research institutions. This ensures dimensional accuracy and surface quality even for 500 mm-class large components. Inspection of internal defects, such as voids and resin accumulation, is a critical evaluation item for large parts. Although in-house machining and coating are not available, collaboration with partner companies enables secondary processing and final assembly, establishing a comprehensive quality assurance framework.

【Application Potential】
Large 500 mm-class CFRTP components can be applied to lightweight panels, covers, and structural parts. Replacing metal components—such as motor housings—with CFRTP reduces weight, contributing to improved fuel efficiency and operational efficiency. Furthermore, combining CFRTP with bio-based resins such as PLA and PA11 enables product differentiation as environmentally sustainable solutions.

【Summary】
Large-scale CFRTP component molding requires both high-capacity equipment and a robust quality assurance system. Kawamura Kikai is equipped with a 200-ton press, supports mold sizes up to 1200 × 1500 mm, and can produce 500 mm-class components. Through inspection capabilities and collaboration with partner companies and research institutions, the company ensures reliable development of large CFRTP parts, making it a strong partner for such projects.

【Contact Information】
Kawamura Kikai Co., Ltd.
Head Office: 2-4 Shimizu-cho, Itabashi-ku, Tokyo 【Composite Division】
Hanazono Factory: 10 Kitane, Fukaya-shi, Saitama 【Metal Press Division】
Website: https://www.kawamura-kikai.co.jp
Inquiry / Quotation: https://www.kawamura-kikai.co.jp/contact/
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