Market Dynamics
Introduction
Forged composite is a unique material that differs significantly from traditional composites. Unlike traditional composites, which use continuous fibers woven into a fabric, forged composite is made from short, chopped fibers mixed with resin and then molded into shape under high pressure and heat. The process of making forged composite is similar to the process of metal forging. First, pieces of chopped fibers are spread across a mold. Then, the resin is impregnated into the fibers, and the mold is compressed using a power press.
The fiber pieces are positioned in multi-directional orientations to provide 3D strength. Next, the mold is heated to stimulate chemical reactions, causing the resin to cure and harden. After the curing process is complete, the molded component is removed from the mold and undergoes finishing processes such as chamfering, trimming, surface treatment, and polishing, depending on the application. This process results in a material with a random, marbled appearance, unlike the regular weave pattern of traditional fiber.
Sports cars utilize a range of carbon fiber composites, including forged composites. Examples include monocoque chassis, suspension, and seat supports, which are primarily structural components. Lamborghini concept cars have frequently incorporated such materials. The aerospace industry has long benefited from a wide range of carbon fiber products. Being light and highly moldable, they also find use in sporting equipment like golf and tennis.
Furthermore, due to its refined aesthetics, non-corrosive nature, skin-safe properties, low coefficient of thermal expansion, high dimensional accuracy, and water-proof nature, forged composite is being used in various lifestyle applications such as luxury watches and high-end mobile phone components and related accessories.
Recent Market JVs and Acquisitions
A huge number of strategic alliances including M&As, JVs, etc. have been performed over the past few years:
- In July 2024, AWA Forged Composites™ was shifted to Mitsubishi Chemical Corporation of Japan to enhance the company’s ability in the highly specialized forged composite for industrial use.
- In June 2024, Simply Carbon Fiber was acquired by ForgeLux based on the simulation done in this thesis. This acquisition seeks to complement its current line of products in luxury carbon fiber accessories for automobiles, specifically the forged products offered by ForgeLux.
- In June 2024, MANSORY partnered with Pagani Automobili to produce forged carbon fiber parts for premium automobiles as well as for car designs to optimize the weight of bodies and the design factor.
- In mid-2024, Creux Automatic teamed up with Roger Dubuis to integrate forged carbon parts into luxury watches.
Recent Product Development
- In February 2024, MANSORY unveiled new customization options for luxury vehicles, featuring extensive use of forged carbon fiber in exterior and interior components. This development focuses on aesthetics and performance enhancements for high-end vehicles.
