Custom Design & Prototyping Tips

Custom Design & Prototyping Tips

Optimize your carbon fiber rod/tube/plate designs for manufacturability, performance and cost

Design Optimization

  • Layup Orientation: Use 0°/90° for axial strength (rods/tubes) or ±45° for torsion resistance
  • Dimension Tolerance: Keep critical tolerances ≥0.1mm (avoid over-tight specs that increase cost)
  • Edge Design: Add fillets (radius ≥1mm) to prevent delamination in plates/tubes
  • Machining Holes: Place holes ≥2x diameter from edges to avoid stress concentration

Prototyping Best Practices

  • Start with 1-2 prototypes (avoid over-ordering early stage)
  • Provide 3D CAD files (STEP/IGES) for accurate quoting and production
  • Test for key performance metrics (tensile strength, straightness, load capacity)
  • Communicate volume plans to Relia – we optimize prototypes for mass production scalability

Relia Prototyping Process

1

Design Review

Free engineering review of your CAD files

2

Prototype Production

7-10 business days for standard prototypes

3

Testing & Feedback

Provide test data and design adjustments

4

Final Production

Scale to mass production with validated design

Common Design Mistakes to Avoid

  • Designing carbon fiber parts like metal parts (carbon fiber performs best with optimized layup, not just thickness)
  • Ignoring machining limitations (small holes <1mm increase production difficulty and cost)
  • Overlooking surface finish requirements (specify matte/glossy/sanded upfront to avoid rework)
  • Not accounting for thermal expansion (Relia can advise on dimensional stability for high-temp applications)