The Quest for the Perfect Carbon-Kevlar Panel: In-House Prototyping at Nikocarbonworks

Over the years here at Nikocarbonworks, one request has consistently landed in our inbox more than almost any other: custom panels featuring this exact, striking carbon-Kevlar hybrid weave pattern. There is something undeniable about the look and mechanical character of carbon combined with aramid fiber, and customers have naturally wanted to see it integrated into our catalog.

The Roadblock: Vacuum Infusion and CNC Frustration

For a long time, we tried taking the shortcut. We purchased completed panels from external suppliers utilizing standard manufacturing methods—primarily vacuum infusion.

While vacuum-infused panels look decent off the roll, they presented a massive headache in the workshop. No matter how precise our feed rates were or how dialed-in our cutting bits were, vacuum infusion inherently leaves microscopic voids, uneven resin distribution, and lower fiber compaction. When you try to CNC route material with high-toughness aramid fibers like Kevlar, a less-than-perfect cure and lower density lead to dreaded fiber pull, fuzzy top layers, and delamination risks. Years of fighting these outsourced panels left us deeply frustrated. We refuse to put our name on a component that doesn't meet our strict precision and finish standards.

Taking Control: Heat, Extreme Pressure, and Aerospace Resin

We finally decided that if we wanted it done right, we had to do it ourselves.

We moved production entirely in-house, adopting a rigorous, uncompromising manufacturing process. Instead of relying on traditional infusion, we now build our panels from the ground up using aerospace-grade structural epoxy, controlled heat, and extreme pressure via our custom heated compression molding system.

It is an undeniably slower, more labor-intensive, and higher-cost process. But the results speak for themselves: completely void-free, highly uniform, dense composite plates that machine cleanly, hold tight tolerances, and boast a brilliant Class-A surface finish.

What’s Next?

We are currently in the final phases of prototyping and testing our new in-house carbon-Kevlar panels.

We couldn't be more excited to bring this material out of the lab and into production. Soon, you’ll be able to order your favorite flat CNC'ed items from our catalog—ranging from custom automotive trims to precision instrument components—configured in this stunning hybrid carbon-Kevlar weave.

Stay tuned for our official product launch updates as we cross the finish line!