Forged Carbon is a composite material known for its unique carbon look. This technique was originally developed for the aerospace industry but has become especially popular through luxury car brands such as Lamborghini, Ferrari, and Pagani. Think of interior components, body panels, or even high-end watch cases, all featuring that distinctive carbon pattern. But did you know you can create this look yourself?
In this article, we explain what Forged Carbon is, what you can do with it, and how to make it step by step.
Forged Carbon (also called chopped or pressed carbon) is a composite material made from randomly oriented chopped carbon fibres that are compressed with a resin, usually epoxy. Unlike traditional woven carbon fibre (which has a recognisable woven structure), Forged Carbon has a marbled, textured appearance. This gives the material a striking visual effect, primarily used for decorative purposes in luxury cars.
Forged Carbon is often chosen for aesthetic reasons, but it also provides structural strength. Common applications include:
Ensure you have a good mould of the desired part. Apply multiple layers of release wax or a suitable release agent so that the final product can be easily removed. Polish the surface if a glossy finish is desired. A matte mould will produce a matte finish, and a glossy mould will produce a glossy finish.
Apply a generous layer of epoxy in the mould. Any suitable epoxy can be used, but pay attention to the Tg value (heat resistance). We recommend RESION Super Clear Epoxy (Tg ~70°C) or Westlake L635 epoxy laminating resin (Tg ~90°C)
Sprinkle the chopped carbon fibres into the mould immediately after applying the epoxy. Use fibres of varying lengths for a playful, random pattern.
Use a brush to apply more epoxy and remove air bubbles, ensuring all fibres are fully saturated.
For extra strength, additional layers of composite material can be applied, such as fibre glass or carbon fabric. Lay the fabrics, impregnate with epoxy, and carefully remove air bubbles using a de-airing roller.
For the best results, we recommend using vacuum infusion. This helps remove air and presses the material firmly against the mould. Note: the vacuum does not move the fibres, so ensure they are correctly positioned beforehand. For more information, see our guide: Vacuum Infusion | How to laminate a panel using vacuum infusion.
Allow the part to fully cure, then carefully remove it from the mould. You now have a unique piece with the characteristic Forged Carbon look!
Optionally, you can sand and finish the surface with a clear coat or epoxy top layer for extra gloss and protection. Polishing the surface can also achieve a high-gloss finish.
Specialist tip: The secret to a beautiful Forged Carbon finish is balancing the amount of fibres and epoxy. Too much epoxy results in a dull, heavy surface, while too little leaves dry spots. Work slowly, evenly, and practice with small test pieces.
Do you want to create Forged Carbon yourself? In our webshop, you’ll find everything you need, from epoxy resins to chopped carbon fibres and release agents.
Feel free to contact our specialists — we’re happy to help you make your Forged Carbon project a success!
Do you have a specific question? Call one of our specialists for free advice +3185 0220090
