Table of Contents:
Material Selection for Custom Parts: Carbon Fiber vs. Metal
- February 10, 2025
- Tony
- Last updated October 21, 2025 By Lucy
Material selection is critical in the manufacturing of custom parts. Different material properties determine the performance, longevity, and manufacturing cost of the part.
Choosing the wrong material can lead to part failure and costly redesigns. Let me share practical insights from my experience to help you make the right decision.
1. Overview of Material Selection for Custom Parts
Importance of material selection for custom parts
Choosing the right material for custom parts is crucial as it affects performance, durability, cost, and application. Different materials offer unique benefits in strength, weight, corrosion resistance, and conductivity. For example, aerospace industries prefer lightweight carbon fiber, while machining relies on steel or aluminum. The right choice enhances performance and reduces costs.
Common Applications for Carbon Fiber vs. Metal
Feature | Carbon Fiber | Metal |
Weight | Very light, over 50% lighter than metal | Heavier, varies by type (steel, aluminum) |
Strength | High tensile strength | Strong, especially in impact resistance |
Corrosion Resistance | Excellent, resists moisture and chemicals | Varies; some metals need anti-rust treatment |
Rigidity | Stiff but brittle | Strong and impact-resistant |
Conductivity | Non-conductive | Good electrical conductivity |
Processing | Needs specialized machining or 3D printing | Suitable for CNC, casting, stamping |
Uses | Aerospace, racing, medical, sports | Automotive, construction, machinery |
2. Basic Overview of Carbon Fiber vs. Metal
What are carbon fibers?
Carbon fibers are high-performance fiber materials made up of carbon atoms with extremely high strength and low density. It is made primarily through the carbonization of polyacrylonitrile (PAN) or asphalt-based materials and is widely used in aerospace, automotive manufacturing and sporting goods.
What are metals?
Metals are materials with distinct chemical properties, recognized for their excellent electrical and thermal conductivity , as well as their ductility and malleability . Their atoms form a regular lattice structure, giving metals their unique properties, such as luster, strength, and toughness.
Common metals include iron, aluminum, copper, gold, and silver, among others. They can be classified into base metals, precious metals, and rare metals based on their uses, composition, and properties.
3. Performance Comparison of Material Selection: Carbon Fiber vs. Metal
Strength to Weight Ratio
Carbon fiber is strong yet lightweight, offering excellent strength-to-weight performance compared to most metals. However, metals like stainless steel and titanium alloys are denser and excel in impact and wear resistance.
Corrosion Resistance
Carbon fiber is resistant to rust and stable in wet or chemical environments but can corrode when in contact with certain metals like aluminum. Metals such as stainless steel and titanium alloys are highly resistant to corrosion, even in harsh environments.
Heat Resistance
Carbon fiber can degrade at extreme temperatures, while metals like titanium and stainless steel can withstand much higher temperatures, making them more reliable in high-temperature environments.
Processing Difficulty
Processing carbon fiber is more complex, requiring molding or 3D printing , while metals are easier to process with methods like cutting and welding, which are better suited for complex part production.
Cost and Economy
Carbon fiber is more expensive due to higher raw material and processing costs, making it less economical for mass production. Metals have more mature production processes and are more cost-effective, making them suitable for a broader range of industrial uses.
4. Material selection for different types of customized parts
Lightweight design is crucial in automotive industries. Carbon fiber suits high-performance models needing low weight and high strength. Metals work better for structural parts enduring heavy loads. Aerospace requires balance between lightness and strength. Carbon fiber fits fuselages and internal structures.
Automotive parts use carbon fiber for weight reduction and metals for structural strength. Aerospace applications balance carbon fiber’s lightness with titanium’s heat resistance. Medical devices require biocompatible metals, while electronics need conductive materials.
Titanium alloys suit parts exposed to high temperatures and pressures. Medical applications need biocompatible materials. Stainless steel and titanium work for surgical instruments and implants. Carbon fiber fits imaging equipment needing lightweight strength. Electronics use carbon fiber to reduce weight. Aluminum and copper provide electrical conductivity and shielding. Industrial machinery prefers metals for wear resistance. Carbon fiber alternatives help where weight reduction matters.
Case Study: Aerospace Satellite Mounting Bracket
We recently faced an exciting challenge from an aerospace client: create a mounting bracket that could survive the harsh environment of space. The part needed to maintain perfect stability despite violent vibrations and extreme temperature swings.
- Operating temperature range: -150°C to +120°C
- Support 25kg of sensitive equipment
- Total weight under 800 grams
- Withstand vibrations up to 2000 Hz
- Natural frequency above 350 Hz to prevent resonance
The Challenge:
Our Solution: After thorough testing of both titanium and carbon fiber options, we chose carbon fiber (IM7/8552). The results spoke for themselves:
The final bracket weighed just 720 grams – 45% lighter than the titanium version. It held dimensional stability within 0.1mm across all temperature extremes and survived rigorous vibration testing at 15G for two full hours without any issues.
The Outcome: Carbon fiber delivered exactly what we needed. The significant weight reduction translated directly into lower satellite launch costs. Most importantly, the client reported perfect performance after six months in orbit, confirming our material selection was right on target.
5. How to choose the right material for your customized parts?
Choosing the right material is a critical step in the production of custom parts. The right material not only ensures the performance and durability of the part, but it can also help reduce costs and increase productivity. Here are some key factors to consider when selecting a material:
Select materials based on usage environment, performance requirements, budget constraints, and processing methods. Analyze strength, corrosion resistance, and temperature needs. Balance material properties with manufacturing capabilities and cost considerations.
- Usage environment: Consider the environment in which the part will be used, such as high temperature, high humidity or chemical corrosion, and select a material with the appropriate durability.
- Performance requirements: Analyze the part’s requirements for strength, corrosion resistance, abrasion resistance and other properties, and select the optimal material.
- Cost budget: Carbon fiber is relatively costly, so the use of metal materials may need to be weighed against the limited budget.
- Processing method: Combine different processing methods to select the appropriate material. For example, carbon fiber is suitable for molding, while metal is suitable for traditional machining.
6. Conclusion
In the future, with the continuous development of material science, the combination of carbon fiber and metal will be more widely used. When customizing parts, a reasonable choice of materials will effectively improve product performance, reduce costs, and meet the needs of different applications.
