PRODUCTION
The production of high-quality carbon components is a precise and complex processrequiring expertise. With over 30 years of experience, Ilmberger Carbon optimizes its in-house production for superior results. The process begins with precisely cutting prepreg material using a plotter, ensuring efficient material use and uniform alignment for aesthetics. Prepreg carbon, pre-impregnated with resin, enhances strength while reducing weight.
Next, multiple carbon layers are manually laminated into CNC-milled aluminum molds, strategically reinforced for stability and minimal distortion. The mold is then vacuum-sealed and cured in an autoclave, which removes excess resin, further reducing weight.
After curing, careful demolding ensures component integrity, especially for complex shapes like winglets. The mold-facing side becomes the visible surface, maintaining high aesthetic standards inside and out.
Quality control begins immediately, with initial inspections to verify curing and lamination. Defective parts are discarded, ensuring only the highest-quality components make it to production.
Next, a robotic arm precisely cuts edges and larger cutouts, ensuring consistency. While many manufacturers stop here, Ilmberger takes additional steps to enhance durability and aesthetics.
Raw carbon is vulnerable to UV light and weather, which can degrade the resin and causediscoloration. To prevent this, Ilmberger uniquely applies a plastic powder coating on allsurfaces, edges, and holes. This thicker, more durable layer protects against environmental damage and enhances the carbon’s depth effect.
After a second inspection, the part is coated with multiple layers of clear paint in either a glossy or satin finish. The powder coating acts as a primer, ensuring a flawless surfacewithout imperfections like the "orange peel" effect. Glossy parts receive a final polish forperfection.
A rigorous final inspection guarantees that only the highest-quality components leaveIlmberger’s facility, meeting top standards in performance and aesthetics.