Repairing carbon fiber

Pfaff technologies has experience in a wide range of repair methods. Every part that comes through our doors is carefully examined to determine the best method to use. The process chosen will depend on the purpose of the repair. Whether it’s structural, aesthetic, form critical, or a combination of all of these. All of our processes are performed using materials that are matched accordingly. Having a strong foundation in composite manufacturing is crucial in understanding a parts construction.  

Racecar repair

Auto racing is a rough sport, even during a clean race, a race car will sustain wear and damages from minor impacts. While engineers and designers work tirelessly to design parts to be strong and durable; by reinforcing specific damage prone components, and adding wear plates to skid areas, the real world is not as forgiving as simulations and testing. In the unfortunate, but all too common instances, where a larger impact occurs, the cost to get your race car back to a competitive state can be very daunting. This is where Pfaff Technologies can step in to help. We specialize in carbon fiber repair, and have thousands of hours of repair experience with some of the most successful modern race cars.

Cost benefits

Repairing the carbon fiber components of your race car, can save you tens of thousands of dollars each racing season. Why would a choose not to have a part repaired? Most likely, it’s because they can’t find an experience facility which specializes in the repair of high-performance composites. In many scenarios, the cost presented for a repair by a small shop, will surpass the cost of a new component. Our facilities, and our workflows are designed on a foundation of race car and high-performance road car repairs. The cost savings you ultimately benefit from, are a result of our investment in our team and our business.

Performance benefit

Maintaining a race cars overall form can do wonders for aerodynamic and downforce efficiency. How do we know? Our engineers have spent hours gathering real world data during competition endurance racing. Data read before and after a component has been compromised, shows a significant loss of downforce. Something that may visibly seem like minor damage, can result in a loss of hundreds of pounds of downforce. If you reference racing history, more specifically the multiple close finishes Pfaff Motorsports has had over the years, you will see the importance of keeping the car in top form.

The Pfaff Technologies difference

We have thousands of hours of repair experience with a wide range race cars and road cars. The value in repairing parts from many different manufacturers and applications, is the library of knowledge built by seeing how different composite engineers approach the part design. We see what works, and what doesn’t. When possible, we can implement the best possible version of a repair to add extra strength and durability to the component. 

Our repair techniques are based on a foundation of designing and manufacturing carbon fiber components in house. This means, we know carbon fiber inside and out, literally. We stay on top of leading-edge technologies in equipment, as well as materials. We continuously refine our processes, and choose the best materials with the highest performance. We do the work, so you don’t have to.

Modern technologies

At Pfaff technologies we stay on the leading edge of advancements in composites and manufacturing technologies. We have the capabilities to perform repairs on parts that may seem destined for the trash bin. From minor repairs, to scenarios where an entire section of a component is missing, we have the equipment and skills necessary to perform a strong, and true to form repair. With in house 3D scanning, 3D printing and CNC machining, paired with experienced professionals in each field, we provide unparalleled quality and high performing results.

Our Process

Pfaff technologies has experience in a wide range of repair methods. Every part that comes through our doors is carefully examined to determine the best method to use. The process chosen will depend on the purpose of the repair. Whether it’s structural, aesthetic, form critical, or a combination of all of these. All of our processes are performed using materials that are matched accordingly. Having a strong foundation in composite manufacturing is crucial in understanding a parts construction.

Here is a list of what we address before performing a repair.

-          Types of fabrics

-          Fabric weight

-          Type of weave

-          Layup schedule

-          Weave orientations

-          Reinforced areas

-          Core structures

-          Custom Inserts

-          Specialized attachment parts

Composite parts can come from many different manufacturers throughout the world, and each of these manufacturers build their parts uniquely. Some of the materials and components used can only be sourced through specialty suppliers. The advantage of performing repairs on a wide variety of makes and models, is that we keep stock of these specialized materials and components. In scenarios where a material is unavailable, we use our expertise to decide on a suitable substitute. For specialty components that are unavailable for purchase, our skilled team can reverse engineer and recreate a component completely.

Making your first decision, the right decision

About 80% of repairs on a race car will happen to the same area multiple times. This means that a previously repaired area has to be prepped multiple times to perform repairs throughout a racing season. If a repair is performed haphazardly the first time, whether it be that a substandard method was used, the wrong materials chosen, or both, the cost of backtracking that work can add a significant amount of time to subsequent repairs. By choosing a single service provider for your composite maintenance, the overall amount of repair time will be reduced, saving you money.

In addition to race car repair, Pfaff technologies also provides the following services:

-          Carbon fiber repair, refinishing, restoration – Road cars, exotics, classics, collectors

-          Bespoke part manufacturing

-          Low production part manufacturing

-          Custom composite tooling

-          Jigs & fixturing

-          Engineering & Design consultation

-          Workflow design

-          3D printing

-          3D scanning, Inspection & Reverse engineering

-          CNC machining – carbon fiber

-          CNC machining – mechanical parts

-          Motorsport consultation

Contact us today, to find out how Pfaff Technologies can add value to your motorsport endeavours.