ZOLTEK PX35
In the world of materials, ZOLTEK PX35 has emerged as the industrial carbon fiber –one that is both affordable and delivers a strength to weight performance equal to or better than many “aerospace’ grades. It is made from our abundant textile-based precursor and manufactured in a proprietary high-throughput process which results in affordable fiber without sacrificing strength or stiffness.
ZOLTEK PX35 is the low-cost commercial carbon fiber that has revolutionized the carbon fiber industry and paved the way for carbon fiber to break into a variety of new applications. Our sustainable pricing structure is independent of the volatile aerospace industry, and is designed to compete with other primary building materials.
Spool-to-Spool Consistency — By vertically integrating the process from precursor manufacturing to carbonization and maintaining ISO 9001:2008 ad AS9100 certifications, ZOLTEK PX35 continues to exhibit superior levels of consistency from spool to spool for critical properties and characteristics.
| SI | US | |
|---|---|---|
| Tensile Strength | 4137 MPa | 600 ksi |
| Tensile Modulus | 242 GPa | 35 msi |
| Electrical Resistivity | 0.00155 ohm-cm | 0.00061 ohm-in |
| Density | 1.81 g/cc | 0.065 lb/in3 |
| Fiber Diameter | 7.2 microns | 0.283 mils |
| Carbon Content | 95% | |
| Yield | 267 m/kg | 397 ft/lb |
| Spool Weight | 5.5 kg, 11 kg | 12 lb, 24 lb |
| Spool Length | 1500 m, 3000 m | 1640 yd, 3280 yd |
DNV-GL has granted approval to Zoltek PX35-1 Multi-Compatible Sizing Tow and Uni-Directional Fabrics, as well as, PX35-7 VE Sizing for Vinyl Ester Compatible Tow an Uni-Directional Fabrics for use in wind energy and marine applications.
ZOLTEK PX35 Chopped Fiber
Chopped carbon fiber is a widely preferred material used in injection and compression molding applications. The resulting product or components are remarkably durable, corrosion-resistant, and incomparably rigid. Examples include machine parts and gears susceptible to long runs with minimal wear and tear. Designed for specific applications requiring cleaner and more consistent flow rates, ZOLTEK’s signature line of chopped carbon fiber materials are produced to have a high bulk density value. Often compounded with general engineering thermoplastics (e.g., PC, Nylon, etc.) and high-temperature thermoplastic resins (e.g, PEEK, PEI, etc.), the resulting composite offers an industry-leading strength to weight ratio ideal for a variety of applications requiring a stronger and more rigid carbon fiber material. In addition, ZOLTEK’s line of chopped carbon fibers distribute easily during compounding and improve the process and product performance as a result. ZOLTEK PX35 Chopped Fibers are versatile and readily available in a pellet, flake, or stick form. Learn more about our collection of chopped fiber products below.
ZOLTEK’s newly-developed Type-95 chop fiber format is characterized by a series of industry-leading benefits that make it an ideal solution for a variety of unique applications. Its high bulk density values allow for cleaner and more consistent flow rates. This product maintains its integrity from the package, into, and through the hopper. It distributes easily during compounding, thus improving overall process and product performance.
ZOLTEK’s Type-95 chopped fiber also has excellent mechanical and electrical properties including high strength and modulus, low density, electrical conductivity, dimensional stability, low thermal expansion, and excellent friction/wear properties.
Recommended Use: Polyamides
Applications: RFI/EMI shielding of electronic devices, Wear-resistance of structural/mechanical parts, Weight reduction and dimensional stability in automotive components
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 2.75% by weight | 2.75% by weight |
| Moisture Content | 0.20% maximum | 0.20% maximum |
| Unpacked Bulk Density (minimum) | 350 g/L | 21.85 lb/ft3 |
| Fiber Length (nominal) | 6 mm | 0.25 in |
| Typical Properties | Nylon(PA66) SI | Nylon(PA66) US | Nylon(PA6) SI | Nylon(PA6) US |
|---|---|---|---|---|
| Carbon Fiber Loading | 30% | 30% | 30% | 30% |
| Tensile Strength | 274 MPa | 39.74 ksi | 261 MPa | 37.85 ksi |
| Tensile Elongation at Break | 2.0% | 2.0% | 1.9% | 1.9% |
| Flexural Strength | 372 MPa | 53.95 ksi | 372 MPa | 53.95 ksi |
| Flexural Modulus | 19.6 GPa | 2.89 msi | 20 GPa | 2.96 msi |
| Charpy Impact Strength (V-Notch) | 8.0 kJ/m2 | 3.80 ft-lb/in2 | 9.0 kJ/m2 | 4.28 ft-lb/in2 |
ZOLTEK’s Type-83 chop fiber format is characterized by a series of industry-leading benefits that make it an ideal solution for a variety of unique applications. Its high bulk density values allow for cleaner and more consistent flow rates. This product’s compact pellet form maintains its integrity from the package, into, and through the hopper. Additionally, ZOLTEK’s Type-83 chop fiber distributes easily during compounding, thus improving overall process and product performance.
ZOLTEK’s Type-83 chopped fiber also has excellent mechanical and electrical properties including high strength and modulus, low density, electrical conductivity, dimensional stability, low thermal expansion, and excellent friction/wear properties.
Recommended Use: High-Temperature Thermoplastics (HTTP): PEEK, PEI, PPA, PAI, PES, PSU
Applications: High operating temperature environments where excellent chemicals resistance, electrical properties, heat aging, dimensional capability, and mechanical properties are required.
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 1.5±0.5% by weight | 1.5±0.5% by weight |
| Moisture Content | 0.20% maximum | 0.20% maximum |
| Unpacked Bulk Density (minimum) | 350 g/L | 22 lb/ft3 |
| Fiber Length (nominal) | 6 mm | 0.25 in |
| Typical Properties | PEI | PEEK | |||
|---|---|---|---|---|---|
| SI | US | SI | US | Method | |
| Carbon Fiber Loading | 40% | 40% | 40% | 40% | - |
| Tensile Strength | 190 MPa | 27 ksi | 228 MPa | 33 ksi | ASTM D638 |
| Tensile Modulus | 26 GPa | 3.7 msi | 31 GPa | 4.4 msi | ASTM D638 |
| Elongation | 1.5% | 1.5% | 1.4% | 1.4% | ASTM D638 |
| Flexural Strength | 317 MPa | 46 ksi | 360 MPa | 53 ksi | ASTM D790 |
| Flexural Modulus | 23 GPa | 3.4 msi | 28 GPa | 4.1 msi | ASTM D790 |
| Izod Impact - Notched | 64 J/m | 1.2 ft-lb/in | 60 J/m | 12.1 ft-lb/in | ASTM D256 |
| Izod Impact - Unnotched | 603 J/m | 11.3 ft-lb/in | 700 J/m | 113 ft-lb/in | ASTM D256 |
ZOLTEK’s Type-65 format is characterized by a series of industry-leading benefits that make it an ideal solution for a variety of unique applications. Its high bulk density values allow for cleaner and more consistent flow rates. This product maintains its integrity from the package, into, and through the hopper. Plus, ZOLTEK’s Type-65 chopped pellet distributes easily during compounding, thus improving overall process and product performance.
ZOLTEK’s Type-65 chopped fiber also has excellent mechanical and electrical properties including high strength and modulus, low density, electrical conductivity, dimensional stability, low thermal expansion, and excellent friction/wear properties.
Recommended Use: Engineering Thermoplastics (ETP): PC, PA, POM, PBT/PET, ABS
Applications: RFI/EMI shielding of electronic devices, Wear-resistance of structural/mechanical parts, Weight reduction and dimensional stability in automotive components
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 2.75% by weight | 2.75% by weight |
| Moisture Content | 0.20% maximum | 0.20% maximum |
| Unpacked Bulk Density (minimum) | 425 g/L | 26.5 lb/ft3 |
| Fiber Length (nominal) | 6 mm | 0.25 in |
| Typical Properties | Polycarbonate | ||||
|---|---|---|---|---|---|
| SI | US | SI | US | Method | |
| Carbon Fiber Loading | 10% | 10% | 30% | 30% | - |
| Tensile Strength | 150 MPa | 18 ksi | 165 MPa | 24 ksi | ASTM D638 |
| Tensile Modulus | 15 GPa | 2.2 msi | 17 GPa | 2.5 msi | ASTM D638 |
| Elongation | 3.3% | 3.3% | 2.3% | 2.3% | ASTM D638 |
| Flexural Strength | 200 MPa | 29 ksi | 259 MPa | 37.5 ksi | ASTM D790 |
| Flexural Modulus | 11 GPa | 1.6 msi | 16 GPa | 2.3 msi | ASTM D790 |
| Izod Impact - Notched | 100 J/m | 1.9 ft-lb/in | 112 J/m | 2.1 ft-lb/in | ASTM D256 |
| Izod Impact - Unnotched | 800 J/m | 15 ft-lb/in | 838 J/m | 15.7 ft-lb/in | ASTM D 256 |
ZOLTEK’s Type-52 format is characterized by a series of industry-leading benefits that make it an ideal solution for a variety of unique applications.
- High strength and modulus
- Low density
- Electrical conductivity
- Dimensional stability
- Low thermal expansion
- Excellent friction/wear properties
Recommended Use: Engineering Thermoplastics (ETP): Polyolefins, such as PE and PP
Applications: RFI/EMI shielding of electronic devices, Wear-resistance of structural/mechanical parts, Weight reduction and dimensional stability in automotive components
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 1.00% by weight | 1.00% by weight |
| Moisture Content | 0.20% maximum | 0.20% maximum |
| Unpacked Bulk Density (minimum) | 300 g/L | 18.7 lb/ft3 |
| Fiber Length (nominal) | 6 mm | 0.25 in |
| Typical Properties | |||
|---|---|---|---|
| SI | US | Method | |
| Carbon Fiber Loading | 30% | 30% | - |
| Tensile Strength | 129 MPa | 18.7 ksi | ASTM D638 |
| Tensile Modulus | 13.6 GPa | 1.96 msi | ASTM D638 |
| Elongation | 3% | 3% | ASTM D638 |
| Flexural Strength | 174 MPa | 25.2 ksi | ASTM D790 |
| Flexural Modulus | 15 GPa | 2.18 msi | ASTM D790 |
| Izod Impact - Notched | 67 J/m | 1.14 ft-lb/in | ASTM D256 |
| Izod Impact - Unnotched | 499 J/m | 8.45 ft-lb/in | ASTM D256 |
ZOLTEK’s PX35 Type-48 fibers provide excellent mechanical and electrical properties for reinforcement in thermoplastic molding compounds requiring high strength and modulus, low density, electrical conductivity, dimensional stability, low thermal expansion and excellent friction/wear properties.
Recommended Use: PBT/PET, PA (nylon)
Applications: Injection molding of articles for use as components in applications requiring static dissipation and/or EMI shielding. Such articles include electronic devices, dust handling equipment, and notebook computer enclosures.
| Material Overview | SI | US |
|---|---|---|
| Sizing Chemistry | Polyester | Polyester |
| Sizing Content | 7.5% by weight | 7.5% by weight |
| Moisture Content | 0.30% maximum | 0.30% maximum |
| Compression Ratio | 0.50 minimum | 0.50 minimum |
| Unpacked Bulk Density (minimum) | 200 g/L | 12.5 lb/ft3 |
| Fiber Length (nominal) | 8 mm | 0.33 in |
| Typical Properties | Nylon (PA66) | mPPO | |||
|---|---|---|---|---|---|
| SI | US | SI | US | Method | |
| Carbon Fiber Loading | 30% | 30% | 10% | 10% | - |
| Tensile Strength | 240 MPa | 35 ksi | 90 MPa | 13 ksi | ASTM D 638 |
| Tensile Modulus | 21 GPa | 3.0 msi | 15 GPa | 2.1 msi | ASTM D638 |
| Elongation | 1.90% | 1.90% | 1.20% | 1.20% | ASTM D640 |
| Flexural Strength | 350 MPa | 51 ksi | 150 MPa | 21 ksi | ASTM D790 |
| Flexural Modulus | 17 GPa | 2.5 msi | 10 GPa | 1.5 msi | ASTM D790 |
| Izod Impact - Notched | 80 J/m | 1.5 ft-lb/in | 74 J/m | 1.4 ft-lb/in | ASTM D256 |
| Izod Impact - Unnotched | 680 J/m | 13 ft-lb/in | 280 J/m | 5.2 ft-lb/in | ASTM D4812 |
ZOLTEK’s Type-45 format is characterized by a series of industry-leading benefits that make it an ideal solution for a variety of unique applications. Its high bulk density values allow for cleaner and more consistent flow rates. This product maintains its integrity from the package, into, and through the hopper. Plus, ZOLTEK’s Type-45 chopped pellet distributes easily during compounding, thus improving overall process and product performance.
ZOLTEK’s Type-45 chopped fiber also has excellent mechanical and electrical properties including high strength and modulus, low density, electrical conductivity, dimensional stability, low thermal expansion, and excellent friction/wear properties.
Recommended Use: Engineering Thermoplastics (ETP): PC, PA, POM, PBT/ PET
Applications: RFI/EMI shielding of electronic devices, Wear-resistance of structural/mechanical parts, Weight reduction and dimensional stability in automotive components
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 2.75% by weight | 2.75% by weight |
| Moisture Content | 0.20% maximum | 0.20% maximum |
| Unpacked Bulk Density (minimum) | 425 g/L | 26.5 lb/ft3 |
| Fiber Length (nominal) | 6 mm | 0.25 in |
A low-cost alternative in thermoplastic applications, ZOLTEK’ PX35 Flake Type chopped fibers provide ready impregnation of thermoset resins, with the capability to mold complex shapes. In a variety of application a small portion of the matrix-specific product can be replaced with chopped flake carbon fibers resulting in negligible impact to composite properties at lower costs. The resultant carbon fiber/ resin matrix composites offer an industry-leading high strength-to-weight and stiffness-to weight ratios.
Recommended Use: Thermoset resins: Epoxy, Vinyl Ester, Unsaturated Polyester, and Phenolic.
Applications: Automotive, Aerospace, Chemical Industry, Construction, Military, Sporting Goods
| Material Overview | SI | US |
|---|---|---|
| Sizing Content | 1.5% by weight | 1.5% by weight |
| Moisture Content | 0.50% maximum | 0.50% maximum |
| Unpacked Bulk Density (Minimum) | 350 g/L | 22 ft/lb3 |
| Fiber Length (nominal) | 3, 6, & 13 mm | 0.125, 0.25, & 0.50 in |
ZOLTEK’s PX35 unsized chopped fibers provide distribution of individual filaments for applications requiring full filament bundle dispersion.
Recommended Use: Applications requiring full dispersion of fiber bundles
Applications: Carbon papers, infrastructure
| Material Overview | SI | US |
|---|---|---|
| Sizing Chemistry | None | None |
| Moisture Content (wet) | 25% approximately | 25% approximately |
| Fiber Length (nominal) | 3 mm 6 mm 13 mm 25 mm 50 mm | 0.125 in 0.25 in 0.50 in 1.0 in 2.0 in |
ZOLTEK PX35 Continuous Tow
ZOLTEK PX35 Continuous Tow is the premier commercial carbon fiber on the market. It is a 50K filament fiber manufactured from polyacrylonitrile (PAN) precursor, and is available with a range of sizings for optimal processing and compatibility with a variety of resin systems. ZOLTEK’s quality system focuses on spool-to-spool consistency yielding low coefficients of variation.
| Material Overview | SI | US |
|---|---|---|
| Tensile Strength | 4,137 MPa | 600 ksi |
| Tensile Modulus | 242 GPa | 35 msi |
| Elongation | 1.7% | 1.7% |
| Electrical Resistivity | 0.00155 ohm-cm | 0.00061 ohm-in |
| Density | 1.81 g/cc | 0.065 lb/in3 |
| Fiber Diameter | 7.2 microns | 0.283 mils |
| Carbon Content | 95% | 95% |
| Yield | 267 m/kg | 397 ft/lb |
| Textile Units | 267 m/kg | 33700 denier |
| Spool Weight | 5.5 kg, 11 kg | 12 lb, 24 lb |
| Spool Length | 1,500 m , 3,000 m | 1,640 yd, 3,280 yd |
ZOLTEK PXFT carbonized felts are produced from 100% ZOLTEK OX felts; that are continuously carbonized and supplied in roll form. ZOLTEK PXFT carbon felts can be used in many applications, including: stationary energy storage batteries, high temperature furnace linings, acid gas mist eliminators and as a carbon composite materials. Customers can apply their own post treatments and the felt is easy to process into customer specific designs.
| Felt Material Overview | |
|---|---|
| Carbon Content | 95% |
| Fiber Diameter | 7-9 µm |
| Fiber Density | ~1.78 g/cc (0.064 lb/in3) |
| BET Surface Area | ~1 m2/g |
| Trace Metals | Fe < 20 ppm, Na < 30 ppm, Ca < 20 ppm |
| Material Overview | PXFT FT-1750 | PXFT FT-1750 | PX35 FT1035-100 | PX35 FT1035-100 | PXFT FT-540 | PXFT FT-540 | PXFT-450 | PXFT-450 | PXFT FT-305 | PXFT FT-305 | PXFT FT-250 | PXFT FT-250 | PXFT FT-50 | PXFT FT-50 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| SI | US | SI | US | SI | US | SI | US | SI | US | SI | US | SI | US | |
| Width | 98 cm | 39 in | 98 cm | 39 in | 98 cm | 39 in | 98 cm | 39 in | 98 cm | 39 in | 98 cm | 39 in | 80 cm | 31.5 in |
| Areal Weight | 1,750 gsm | 51.6 opsy | 1035 gsm | 30.5 opsy | 540 gsm | 15.9 opsy | 450 gsm | 13.3 opsy | 305 gsm | 9.0 opsy | 265 gsm | 7.8 opsy | 50 gsm | 1.5 opsy |
| Thickness | 16.5 mm | 0.65 in | 12.0 mm | 0.47 in | 6.0 mm | 0.24 in | 4.8 mm | 0.19 in | 4.0 mm | 0.16 in | 3.4 mm | 0.13 in | 1.0 mm | 0.039 in |
| Felt Bulk Density | 0.11 g/cc | 0.00397 lb/in3 | 0.09 g/cc | 0.00325 lb/in3 | 0.09 g/cc | 0.00325 lb/in3 | 0.09 g/cc | 0.00325 lb/in3 | 0.08 g/cc | 0.00289 lb/in3 | 0.08 g/cc | 0.00289 lb/in3 | 0.05 g/cc | 0.0018 lb/in3 |
| Roll Length | 45 m | 49 yds | 45 m | 49 yds | 45 m | 49 yds | 45 m | 49 yds | 80 m | 87 yds | 80 m | 87 yds | 80 m | 87 yds |
| Electrical Resistivity | 2.2 Ω mm | 2.2 Ω mm | 6.3 Ω mm | 6.3 Ω mm | 3.9 Ω mm | 3.9 Ω mm | 4.0 Ω mm | 4.0 Ω mm | 5.8 Ω mm | 5.8 Ω mm | ~5.0 Ω mm | ~5.0 Ω mm | 66 Ω mm | 66 Ω mm |
| Open Porosity | 94% | 94% | 95% | 95% | 95% | 95% | 95% | 95% | 96% | 96% | 96% | 96% | 97% | 97% |
| Tensile Strength in MD / XMD direction | 0.30 MPa / 0.30 MPa | 0.30 MPa / 0.30 MPa | 0.19 MPa / 0.34 MPa | 0.19 MPa / 0.34 MPa | 0.43 MPa / 0.41 MPa | 0.43 MPa / 0.41 MPa | 0.28 MPa / 0.48 MPa | 0.28 MPa / 0.48 MPa | 0.67 MPa / 0.36 MPa | 0.67 MPa / 0.36 MPa | 0.24 MPa/0.21 MPa | 0.24 MPa/0.21 MPa | 1.47 MPa / 0.51 MPa | 1.47 MPa / 0.51 MPa |
| Elongation in MD / XMD Direction | 18.6%/26.0% | 18.6%/26.0% | 41.5%/39.5% | 41.5%/39.5% | 19.3%/18.1% | 19.3%/18.1% | 18.5% / 18.3% | 18.5% / 18.3% | 13.2% / 16.0% | 13.2% / 16.0% | 13.9%/19.5% | 13.9%/19.5% | 7.9% / 25.5% | 7.9% / 25.5% |
ZOLTEK PX35 milled carbon fiber is specially processed PAN (polyacrylonitrile) based fiber perfectly suitable for high-volume applications that require notable strength and/or electrostatic dissipation. All ZOLTEK milled carbon fiber products are free of any sizings, and our unique in-house milling system ensures the utmost product quality and traceability from raw material through finished product.
| MATERIAL OVERVIEW | PX 35 | PX 35 | PX 30 MF/ME | PX 30 MF/ME |
|---|---|---|---|---|
| SI | US | SI | US | |
| Carbon Content | 95% | 95% | 99% | 99% |
| Electrical Resistivity (Volume) | 0.00155 ohm-cm | 0.00061 ohm-in | 0.0014 ohm-cm | 0.00055 ohm-in |
| Linear Resistivity | 0.0761 Ω/cm | 0.02996 Ω/in | 0.069 Ω/cm | 0.02717 Ω/in |
| Density | 1.81 g/cc | 0.065 lb/in | 1.75 g/cc | 0.063 lb/in3 |
| Bulk Density | 490 g/L | 30.6 lb/ft3 | 465 g/L (MF150) 350 g/L (MF200) | 30.6 lb/ft3 (MF150) 30.6 lb/ft3 (MF200) |
| Fiber Diameter | 7.2 μ | 0.283 mils | 7.2 μ | 0.283 mils |
| Average Fiber Length | 100 μ (MF150) 150 μ (MF200) | 4 mils (MF150) 6 mils (MF200) | 100 μ (MF150) 150 μ (MF200) | 4 mils (MF150) 6 mils (MF200) |
| Filament Shape | Round | Round | Round | Round |
ZOLTEK Multi-Directional Fabrics are produced from our ZOLTEK PX35 continuous carbon fiber tow. ZOLTEK utilizes unique fiber spreading techniques to obtain a wide range of Multi-Directional fabric weights for a varied set of composite part applications. A quick composite part build-up is cost effectively achieved with our diverse weight range of low-cost carbon fabric products. ZOLTEK Multi-Directional Fabrics drapable fabric construction is also ideal for complex shape preforms. Pillar and Tricot stitching patterns are available as needed.
Applications: Automotive, marine, Aircraft, Infrastructure
Recommended Use: Body Panels (Interior/Exterior), Components/Undercarriage, Reinforcement
| Material Fiber Properties | SI | US |
|---|---|---|
| Tensile Strength | 4,137 MPa | 600 ksi |
| Tensile Modulus | 242 GPa | 35 msi |
| Electrical Conductivity | 0.00155 ohm-cm | 0.00061 ohm-in |
| Density | 1.81 g/cc | 0.065 lb/in3 |
| Fiber Diameter | 7.2 microns | 0.000283 in |
| Carbon Content | 95% | 95% |
Ideal for rapidly building part thickness with excellent composite properties, ZOLTEK PX35 allow for higher manufacturing throughput at a lower cost. These prepreg tapes are available in areal weights from 150 gsm to 600 gsm, based on carbon areal weight. Different epoxy resin formulations meet a variety of processing and composite property requirements for tack, toughness, flow in cure, surface finish, cure time, cure temperature, and delivered composite strength and modulus.
Recommended Use: Any, Excellent for hand layup or automated fabrication processes
Applications: Wind energy, automotive, petroleum production, aviation, marine, industrial, other transportation, medical (including x-ray), sports and recreation
| Typical Properties | SI | US | Method |
|---|---|---|---|
| Tensile Strength | 1,850 MPa | 268 ksi | DIN EN ISO 527 |
| Tensile Modulus | 130 GPa | 18.9 msi | DIN EN ISO 527 |
| Compressive Strength | 1,320 MPa | 191 ksi | DIN EN ISO 14126 |
| Compressive Modulus | 125 GPa | 18.1 msi | DIN EN ISO 14126 |
| Interlaminer Shear Strength | 70 MPa | 10 ksi | ASTM D 2344 |
| +/-45 In-Plane Shear Strength | 59 MPa | 8.6 ksi | DIN EN ISO 14129 |
| +/-45 In-Plane Shear Modulus | 4.8 GPa | 696 ksi | DIN EN ISO 14129 |
| Glass Translation Temperature (Tg,G") | 120°C | 248°F | DMA |
ZOLTEK’s™ Pultruded Profiles are pre-cured, thick-ply carbon fiber laminates for ideal structural reinforcement applications. Available in a variety of thicknesses and complex shapes, our pultrusion products deliver optimized properties with high fiber volumes, nearly zero void content, and locked-in filament alignment.
ZOLTEK PX35 carbon fiber tows are fed into our proprietary impregnation and curing process which creates smooth carbon fiber laminates resulting in efficient laydown when building thickness. The specific fiber alignment achieved with pultrusion delivers consistently better overall properties in laminates than any other composite manufacturing process. Depending on the end application, these pultruded profiles are typically produced with a thermoset epoxy or vinyl ester resin in a proprietary low-cost, high-throughput process.
Pultruded profiles are production-ready carbon composites for infrastructure applications, deep sea exploration, wind energy, and other applications benefiting from the unique properties of pultruded carbon fiber parts.
Applications: Wind Energy, Infrastructure, Offshore Drilling, Mining, Other Structural Reinforcement Applications
| Product Feature | Test Method | PX35/Vinyl Ester | PX35/Vinyl Ester | PX35/Epoxy | PX35/Epoxy |
|---|---|---|---|---|---|
| Fiber Volume Fraction (Mean) | ASTM D3171 | 62% | 69% | 65% | 69% |
| Flexural E Modulus (Mean) | ASTM D6272 | 151 GPa | 163 GPa | 135 GPa | 167 GPa |
| Flexural Strain (Characteristic) | ASTM D6272 | 0.88% | 1.02% | 1.1% | 1.04% |
| Interlaminar Shear Strength (Characteristic) | ISO 14130 | 62 MPa | 67 MPa | 69 MPa | 71 MPa |
| Transverse Strength (Characteristic) | ASTM D790/ISO 527 | 72 MPa | 60 MPa | 62 MPa | 108 MPa |
| Axial Tensile Modulus | ISO 527/DIN EN 2561 | 141 GPa | 161 GPa | 144 GPa | 164 GPa |
| Axial Compressive Modulus | ASTM D6641/DIN EN 2850 | 133 GPa | 148 GPa | 135 GPa | 145 GPa |
| Linear Tensile Strain to Failure (Characteristic) | ISO 527/DIN EN 2561 | 1.06% | TBD | 1.2% | 1.09% |
| Linear Compression Strain to Failure (Characteristic) | ASTM D6641/DIN EN 2850 | 0.73% | 0.74% | 0.75% | 0.68% |
* Typical data based on 5mm thick pultruded profiles
ZOLTEK, together with Toray, has developed a new innovative technology and input material for Sheet Molding Compound (SMC) for compression molding. SMC is a material consisting of resin and chopped carbon fiber which is placed into matched metal tooling to mold a finished part.
The new carbon fiber tow product still consists of a large tow (50K), but it is now split into 3K sub tows, so that when chopped it breaks apart into a homogeneous isotropic bed of small tow carbon fiber which is easily wet out in the SMC process. The resulting molding compound produces a revolutionary strong and stiff composite part suitable for automotive and other applications.
Final parts molded from SMC benefit from a high throughput compounding process coupled with low cost inputs (resin and fiber). Further, the molding process is highly efficient with very low waste. More than 97% of the compound is used in the final molded part with very little edge trim or other scrap.
| Typical Properties - Cut Coupons, Average 0/90: | |||
|---|---|---|---|
| PROPERTY | METHOD | UNITS | VALUE |
| Specific Gravity | ASTM D792 | g/cm3 | 1.41 |
| Tensile Modulus | ASTM D638 | GPa | 34.0 |
| Tensile Strength | ASTM D638 | MPa | 217 |
| Flexural Modulus | ASTM D790 | GPa | 27.6 |
| Flexural Strength | ASTM D790 | MPa | 432 |
| Impact Strength N -Izod | ASTM D4812 | J/m | 483 |
| Glass Transition by DMA | ASTM 7028 | °C (Tan Delta) | >192 |
| Water Absorption | ASTM D570 | % | <0.30 |
| DTUL (HDT) | ASTM D648 | °C | >250 |
| Shrinkage | ASTM D6289 | & | 0.01 |
| Flammability | UL 94 | HB |
ZOLTEK has specifically designed continuous tow, chopped fibers, and milled fibers for both general and high-temperature engineering thermoplastics. To further optimize the solutions provided, ZOLTEK has also developed specific sizing technology for all major thermoplastic materials. The end result is a revolutionized approach to thermoplastics in which compounders can achieve physical property improvements that will move thermoplastic into new application areas. With this technology, nylon compounds can replace traditional cast aluminum and Mg applications. PP compounds can compete with higher density filled materials or vertical panel applications. Higher heat materials have already been compounded for use in 3D printed tooling.
Our portfolio of sizings are compatible with Nylons, Polycarbonates, and several high-temperature thermoplastics (PEI, PEEK, PPS, etc.).
Each ZOLTEK PX35 thermoplastic-optimized fiber has its benefits. High bulk density values allow for cleaner, more consistent flow rates. Chopped fiber is available in various lengths for thermoplastic compounding. Milled fiber is available in pellet form of as a dry powder. The compact pellet form maintains its integrity from the package through the hopper and distributes easily during compounding, improving process and product performance
ZOLTEK’s PX35 carbon fiber also has excellent mechanical and electrical properties including electrical conductivity, dimensional stability, and low thermal expansion.
ZOLTEK’s Uni-Directional Fabric (Stitch-Bonded) is produced from our ZOLTEK PX35 50K Continuous Tow Carbon Fiber. In keeping with ZOLTEK’s commitment to providing ideal solutions to a variety of application challenges, this product’s unique fiber spreading techniques enable a wide range of fabric weights and constructions for composite part applications. Specially constructed for enhanced infusibility, ZOLTEK’s Uni-Directional Fabric also allows for a rapid build-up of part thickness. Depending on an application’s unique needs, fabric treatment such as binders can be added to the fabric.
| Composite Properties | SI | US | Method |
|---|---|---|---|
| Tensile Strength | 1,400 MPa | 203 ksi | DIN EN ISO 527 |
| Tensile Modulus | 119 GPa | 17.2 msi | DIN EN ISO 527 |
| Compressive Strength | 980 MPa | 142 ksi | DIN EN ISO 14126 |
| Compressive Modulus | 118 GPa | 17.5 msi | DIN EN ISO 14126 |
| Flexural Strength | 1,290 MPa | 187 ksi | DIN EN ISO 14125 |
| Felxural Modulus | 112 GPa | 16.2 msi | DIN EN ISO 14125 |
ZOLTEK PX35 tow weave carbon fabric is produced from our durable signature ZOLTEK PX35 50K Continuous Tow Carbon Fiber material. As part of our ongoing commitment to providing innovative carbon fiber solutions for a variety of industrial and everyday applications, this product provides a cost-effective quick composite part build-up to achieve a superior aesthetically pleasing designc. Some common applications for this industry-leading tow weave carbon fabric include large composite tooling parts as well as finished composite components for a range of different applications.
| Material Overview | P/TW28-50 | P/TW28-50 | SW48-50 | SW48-50 |
|---|---|---|---|---|
| SI | US | SI | US | |
| Construction | Plain or Twill Weave | Plain or Twill Weave | 5 Harness Satin Weave | 5 Harness Satin Weave |
| Warp Yarn | 1/cm | 2.6/in | 2/cm | 5.1/in |
| Fill Yarn | 1.5/cm | 3.8/in | 2.4/cm | 6.1/in |
| Areal Weight | 960 g/m2 | 28 oz/yd2 | 1,640 g/m2 | 48.4 oz/yd 2 |
| Width | 1,270 mm | 50 in | 1,270 mm | 50 in |
| Thickness | 1.5 mm | 0.055 in | 2.8 mm | 0.093 in |
| Roll Length | 30 m | 32.8 yd | 25 m | 27.3 yd |
| Yarn | ZOLTEKPX35 50K Tow with Epoxy Sizing at 1.5% | ZOLTEKPX35 50K Tow with Epoxy Sizing at 1.5% | ZOLTEKPX35 50K Tow with Epoxy Sizing at 1.5% | ZOLTEKPX35 50K Tow with Epoxy Sizing at 1.5% |
ZOLTEK PX35 Applications
ZOLTEK PX35 is the dominant carbon fiber in the wind turbine industry and is on the forefront of many other applications including infrastructure, automotive, pressure vessels, offshore drillings, and other industrial applications. It is the best value proposition of any other carbon fiber with market-leading properties at a market-leading price.