Carbon composite assembly: choose an adhesive solution

      Bonding carbon fiber composites in industry

Introduced in the 1950s, carbon fibers stand out for their exceptional properties: lightweight, high strength, and corrosion resistance. To create a composite material, these fibers are impregnated with an organic matrix (or resin) and then shaped in a heated mold.

Carbon fiber is a material of choice in many industrial sectors:

✈️ Aerospace: Reduces structural weight to improve energy efficiency.
🚗 Automotive: Enhances performance and reduces the weight of premium vehicles.
🏆 Sports: Optimizes equipment for competition and durability.
🛡 Defense industry: Produces ultra-lightweight and high-strength components.

With its outstanding strength-to-weight ratio, rigidity, and durability, carbon fiber composite is essential for structural and functional components.

However, assembling carbon fiber composites presents challenges. Traditional methods like rivets, screws, or welding can weaken structures and increase component weight.

Structural adhesives offer an effective and durable alternative. Thanks to technological advances, many adhesives now make it possible to bond composites without compromising their mechanical properties.

Some suitable solutions:

• Acrylic or epoxy resin construction adhesives, as well as 1-K and 2-K structural polyurethanes, for robust assemblies.

• Structural adhesive films, specially designed for composites and plastics, using high-performance epoxy resins.

• Low-density reinforcement sealants, ideal for strengthening honeycomb structures in automotive and aerospace construction.

• Acrylic foam adhesive tapes, an effective alternative to rivets and clips for durable fixings.

      Challenges of carbon composite bonding

Why avoid mechanical fasteners?

While rivets, screws, or clips provide immediate holding power, they have several disadvantages:

❌ Material weakening: Drilling creates microcracks in the composite structure.

❌ Stress concentration: Pressure at fastening points can lead to failure zones.

❌ Additional weight: Fasteners add unnecessary weight compared to adhesives.

❌ Compromised aesthetics: Visible fixings impact the final appearance.

Friction welding or heat welding may be alternatives, but these methods are energy-intensive, require costly tools, and limit part geometry.

Advantages of adhesive bonding

✅ Preserves material integrity: No drilling or excessive stress on components.

✅ Even force distribution: Eliminates stress concentrations seen with rivets and welds.

✅ Lightweight assemblies: Adhesives are lighter than mechanical fasteners.

✅ Better resistance to vibration and shock: Adhesives absorb dynamic stresses.

✅ Corrosion protection: Prevents galvanic corrosion between dissimilar metals.

✅ Simplified multi-material bonding: Compatible with composites, plastics, metals, and low surface energy materials (PP, PE, TPO).

✅ Flawless aesthetics: No visible elements, no touch-ups required.

      Applications of carbon fiber composite bonding

Thanks to its lightweight and mechanical strength, carbon fiber is used in demanding industries. Industrial bonding allows for assembly, repair, and reinforcement of components while ensuring optimal performance.

🚴 Carbon fiber bike frame repair

Bonding is essential for repairing cracked or damaged carbon bike frames, restoring rigidity and strength without adding weight.

• Common in high-end cycling

• Ensures performance and safety

✈️ Aerospace and marine industries

Bonding carbon composites is crucial for assembling lightweight and ultra-resistant structures, reducing fuel consumption and improving aircraft performance.

• Weight optimization: Reduces component mass while maintaining strength.

• Enhanced mechanical resistance: Epoxy and structural adhesives withstand mechanical stress and vibration.

• Critical assembly applications: Bonding helicopter leading edges, fuselages, and support structures.

• Aerospace compliance: Adhesives meet FAR 25§853 and ABD0031 standards.

🎯 Sports equipment

Carbon bonding improves impact resistance and mechanical durability while keeping equipment light for optimal performance.
Applications include:

• Windsurf boards

• Fishing rods

• Golf clubs

• Competition bows

• Baseball bats

🏗️ Civil engineering and construction

Bonded carbon fiber reinforces concrete structures without adding weight—ideal for renovation and seismic upgrades.

• Strengthens concrete elements

• Improves mechanical resistance without extra mass

🏎️ Automotive and transportation

Bonding carbon fiber components replaces mechanical fasteners, reducing vehicle weight and improving performance and fuel efficiency.

• Used in racing and premium vehicles

• Improves performance and fuel economy

      Adhesive solutions for carbon fiber composite bonding

Key factors when selecting a structural adhesive

Your assembly requirements, final application, and materials influence the optimal bonding solution. Consider these criteria to choose the right adhesive:

• What materials will be bonded?

• What environment (temperature, humidity, UV exposure)?

• What forces will the joints endure (shear, tension, compression)?

• Does it need chemical resistance (oil, fuel, acids, bases)?

• Are there mechanical challenges (impact, vibration, stress)?

      Adhesives for carbon fiber composite

Adhesives by second substrate type :

📞 Need expert advice or a quote?

Each carbon fiber bonding application has specific requirements for adhesion, mechanical strength, and durability. Adezif experts are ready to help you find the best solution for your needs.

📩 Contact us today!