Xinbo Composites manufactures carbon fiber tubes with different processes, depending on customers’ project requirements, order quantities and budgets.
Roll Wrapping Carbon Fiber Tubes
The roll wrapping process has been developed to give specific advantages over other processes used for carbon tube production. These processes have been enhanced and developed and are now tried and tested to produce tubing lighter, stiffer and stronger than previously possible.
Roll wrapping begins with a precision-ground steel mandrel that defines the tube’s inner diameter and taper. Layers of carbon or fiberglass fabric pre-impregnated with resin (“prepreg”) are applied in controlled orientations to meet target strength, stiffness, and performance requirements. The materials used are pre pregnated carbon fibre cloth, which has different weaves woven into it in unidirectional, 45 degrees, 90 degrees or zero degrees with strictly controlled resin content, which ensures that the tubes produced are the most consistent
Roll wrapped carbon fiber tubes are manufactured by wrapping prepreg carbon fiber plies around a precision mandrel, followed by compaction and curing. This process allows accurate control of fiber orientation, wall thickness, layup sequence, and tube dimensions, making it suitable for structural applications where stiffness, strength, and weight reduction are critical.
Xinbo Composites manufactures custom roll-wrapped carbon fiber tubes with high bending stiffness, precise layup control, lightweight structure, and OEM sizes for UAV, robotics, automation, sports, and industrial applications.
Filament Wound Carbon Fiber Tubes
Filament winding is a manufacturing process where continuous carbon fiber tows are pulled through a resin bath and wound onto a rotating mandrel under controlled tension. The mandrel rotates while a delivery head traverses back and forth, laying fiber at a specific winding angle. This process creates a tube with optimized fiber orientation for the intended load case.
Filament wound carbon fiber tubes are composite cylinders manufactured by winding continuous carbon fiber tows impregnated with epoxy resin around a rotating mandrel at precisely controlled angles. The winding angle, typically between 45° and 90° relative to the tube axis, determines the mechanical properties: a 45° angle provides optimal torsional strength (shear modulus up to 5 GPa), while a 90° (hoop) angle maximizes burst pressure resistance (up to 700 MPa hoop stress). The winding angle, fiber tension, resin content, and curing process determine the tube’s torsional stiffness, hoop strength, axial performance, and dimensional consistency.
Xinbo Composites manufactures custom filament wound carbon fiber tubes for drive shafts, torque tubes, pressure-resistant structures, rollers, masts, and industrial composite applications. OEM sizes, winding angles, wall thicknesses, and surface finishes are available.
Compression Molding Carbon Fiber Tube
Compression molding is manufactured by placing prepreg carbon fiber plies into a matched metal mold, followed by heat and hydraulic pressure curing. Unlike roll-wrapped tubes, which are mainly controlled by a mandrel, compression molding controls both the inner and outer surfaces of the part, making it suitable for shaped tubes and integrated features. The compression molding process offers tight dimensional control, a high strength-to-weight ratio and perfect appearances.
The compression molding process is ideal for carbon fiber square tubes, rectangular tubes, oval tubes, octagonal tubes, hexagonal tubes, bent or cured tubes, D-shaped tubes, custom profiles, and tubes with integrated flanges, bosses, ribs, or mounting features. The matched tooling helps improve dimensional consistency, surface quality, wall thickness control, and repeatability for medium-to-high volume production.
Xinbo Composites customizes compression-molded carbon fiber shaped tubes with tight dimensional control, high strength-to-weight ratio, and OEM designs for robotics, automotive, medical, industrial, and structural applications.
Xinbo Composites customizes carbon fiber shaped tubes with tailored layup design, wall thickness, surface finish, CNC machining, bonding, and assembly options. Parts can be designed for bending stiffness, torsional strength, impact resistance, lightweight structure, or combined load requirements.
Autoclave Molding Carbon Fiber Tube
Autoclave-molded carbon fiber tubes are manufactured by laying prepreg carbon fiber plies onto a mandrel or mold, followed by vacuum bagging and curing under controlled heat and external pressure inside an autoclave. This process provides high laminate consolidation, low void content, and excellent interlaminar strength, making it suitable for demanding structural applications.
Compared with standard roll-wrapped or compression-molded tubes, autoclave-molded carbon fiber tubes are preferred when fatigue resistance, impact performance, laminate quality, and structural reliability are critical. The process is commonly used for aerospace-grade tubes, motorsport components, defense structures, robotic arms, medical equipment, and high-performance industrial applications.
Xinbo Composites provides custom autoclave-molded carbon fiber tubes with tailored fiber layup, wall thickness, diameter, length, surface finish, CNC machining, bonding, and assembly options. Tubes can be designed for bending stiffness, torsional strength, fatigue resistance, lightweight structure, or combined load requirements.
Pultruded Carbon Fiber Tubes
Pultruded carbon fiber tubes are manufactured by pulling continuous carbon fiber rovings through a resin bath and a heated die to form a constant cross-section profile. Because the fibers are mainly aligned in the length direction, pultruded tubes provide excellent axial strength and stiffness with good dimensional consistency and efficient production.
Compared with roll-wrapped or filament-wound carbon fiber tubes, pultruded tubes are best suited for straight profiles, long lengths, stable cross-sections, and cost-sensitive production. The process is commonly used for carbon fiber round tubes, square tubes, rods, strips, beams, and other continuous composite profiles.
Xinbo Composites provides pultruded carbon fiber tubes and profiles with custom dimensions, surface finishes, cutting, drilling, bonding, and assembly options. Pultruded tubes are suitable for lightweight structures where axial load, repeatability, and production efficiency are important.
