Apple Tests Carbon Composite for iPad Housing

In addition to investing in the LiquidMetal process, Apple also is actively investigating the potential for carbon-fiber reinforced plastics (CFRP), the same material used in the Boeing Dreamliner 787. Apple received a U.S. patent yesterday for a fiber-reinforced housing, apparently intended to replace aluminum in the iPad in response to complaints about the device’s weight. The first version of the iPad weighs just 1.5 lb, but the next version may use new materials technologies like carbon fiber to reduce its weight and make e-reading more comfortable.

The patent also covers issues that might create challenges to the design team. These additional claims address issues pertaining to the molding process to create perfect parts suitable for Apple.

[more at Design News]

Carbon-fiber seats by Peter Donders

Belgian designer Peter Donders developed these ultra-light seating furniture pieces made from 462 meters (for the “stone”) and 320 meters (bench) of carbon-fibre under his label morphs. The single string of fibre is twisted around a form that’s removed after forming. Check the Daily Tonic link for images of production and the Peter Donders website for additional pics and information.

[via Daily Tonic]

BMW’s new material investment in carbon fiber

Moving from concepts and piece-meal implementation, BMW AG is going to production with its 2013 Megacity vehicle (MCV). (The concept shown at top and the carbon fiber cockpit shown underneath.) Every body panel and some interior parts will be made using a carbon fiber the company will mold itself, using carbon fiber from BMW’s new joint venture plant between BMW and SGL Group in Wiesbaden, Germany. The two recently had formed a joint venture under which carbon fibers made in the U.S. at a new plant in Moses Lake, Wash., will be used exclusively to create the MCV’s cockpit structure.

BMW reported that one Megacity prototype structure has been crash-tested from three different positions: two in accordance with EuroNCAP regulations and one under U.S. side-impact rules. After the testing, the passenger cell was still intact, confirming the integrity of the composite structure.

[Plastics News story]

[Composites World story]

Sustainable Carbon Fiber Composite?

3D design graduate Neil Conley of Northumbria University has developed a sustainable carbon fiber composite, entitled X Endless.  The project relies on a recent development in composite recycling: a specific pyrolysis method (heat) that that unwinds the carbon fibers from the composites that bind them, allowing them to be re-used.

Conley designed a series of two cremation urns that:

Aim to demonstrate not only the endlessly recyclable potential of the material, but also how relevant material sourcing can re-inject relevance to objects of narrative and poetry.

He points to the mining of aircraft material from their graveyards, where they would otherwise lay unused.

While this method has allowed Neil to mine unlocked carbon fibers from obsolete aircraft and mix them with a bio-resin derived from plant oils to create a new carbon-fibre composite that can reduce and prevent carbon fibre waste, this work is not without its critics.

Check out some of the comments in the Core77 post. Specifically from a commenter Lawrence:

Even if you do burn the resin away, the resulting carbon fiber is so contaminated with soot that it’s strength would decrease dramatically, no one would probably use it for anything aside for decorative purposes.

Check out the rest of the article and get in on the discussion (if you’re into that sort of thing).

[Core77 article]

Wrap Your Skull in Carbon Fiber

[Via Cool Hunting]

“For extreme sports enthusiasts in search of the utmost protection year-round, Bern recently developed a carbon fiber version of their stylish Macon, Baker and Watts styles. Taking advantage of the high-tech material, the extremely lightweight carbon shell withstands powerful punches.

The matte carbon models are available either as an EPS-certified helmet (the standard protection level for action sports) or as a Hard Hat—an ultra-ventilated helmet that uses resilient Brock foam technology to survive multiple impacts. Bern offers appropriate sizes for men and women, and their simple snap-in upgrade system easily transitions helmets from summer to winter sports.

The new shells sell from Bern’s online shop or outdoor sports stores worldwide for about $215.”