Carbon is the ultimate frontier, state-of-the-art, and most resistant material today. Namely, the most recent one still has the most unexpressed potential and opportunities. It is available to everyone, and its use hides issues that can only be solved following a big technological sacrifice. It includes a careful analysis of the materials’ properties, the realisation of a stamp and the testing of the product manufactured.

It is worth pointing out that when discussing carbon, we refer in reality to a composite realised from carbon fibres as a structural component and epoxy resin. The latter serves in practice as the cement that joins the fibres. Here lies, in fact, the carbon’s distinct difference from all other materials: while in normal circumstances it is possible to manufacture products of metal composites from various parts welded together, with the carbon following the processing method starts through “leathers” made up by Carbon Fibres pre-impregnated with resin that is modelled by moulds, from simple shapes to the most varied, geometric shapes resulting either by technical analysis and structures rather than aesthetic parameters.

Inside the mould, the “leathers” are laid out according to their thickness and, of fundamental importance, to the orientation of the latter, it is possible to determine the characteristics of the products’ resistance and elasticity to realise. Conveniently orientating the fibres is also of equal thickness to the product. It is possible to obtain resistant and rigid characteristics that are very different and far superior to classic materials. The material is then compressed in the autoclave and heated; the resin catalyses and hardens.

Finally, it must be said that the carbon processing technologies are still in their early stages. The continuous distribution of this material in extreme industries such as Formula 1 or the aeronautical will undoubtedly have a technological improvement and a reduction of the materials cost.

Fibreglass is a composite material, from glass fibre and plastic resin, in the general polyester background, vinyl ester or epoxy. It has been the first plastic composite material, printable at low temperatures, without pressure and that, properly reinforced, improves the characteristics of mechanical resistance significantly.

The materials used throughout its manufacturing are four:

1. Gelcoat: it represents the side to prepare the artefacts and is applied through manual coating with a double layer. It provides the structure with excellent resistance to shocks, a good thermal resistance, protects from atmospheric agents and ultraviolet rays and the attachment of chemical substances, and gives the structure a continuous and smooth surface.
2. Resin: it has the function of an actual binding agent/bonding agent that, with polymerization, the permanent shape of the bodywork. It has a high resistance concerning high loads and traction.
3. Fibreglass: it consists of applied sheets by hand in three crossed layers (MAT). It provides a high elasticity to the finished material.
4. Polyurethane foam: altered to multilayer phenolic plywood layers for better fixing the furnishings. It comprises thick layers and provides robustness to the structure and technical resistance. It is a self-extinguishing material.

The manufacturing takes place through moulds that can assume whatever geometrical shapes. In the first place, the Gelcoat is laid down, consisting of the first external shell on them. They are laid down and then impregnated with resin, three crossed MAT sheets. Every single time rolled manually to allow better adhesion to their moulds and curves. Following this operation, it is possible to obtain outstanding robustness and elasticity, joined to a remarkable dimensional uniformity in every part of the manufactured product. On the resin layers, the polyurethane foam is then applied in sheets.