Composite Castings LLC (CC) announces the launch of its new, lightweight, carbon fiber composite, 4-cylinder engine blocks. This novel engine block design was developed by Matti Holtzberg, President and founder of Composite Castings, based in West Palm Beach, Florida, USA. Extensive research resulted in the selection of Toho Tenax America's Tenax® brand carbon fiber as the reinforcement for the base epoxy resin.
The resulting high performance compound is molded into the finished engine block profile using CC.s proprietary molding process (patented and patent pending) that uses low cost tooling and provides for faster cycle times compared to conventional CFRP molding methods.
The new engine blocks are 45-50% lighter in weight than a comparable aluminum block. The weight saving is a significant competitive advantage in the performance engine business and will attract a lot of interest from the worldwide automotive industry where weight is so critical, particularly in hybrid cars. A composite block is cast to a net shape, which: eliminates secondary machining; significantly reduces NVH due to the relationship between fiber and resin; does not corrode; and represents a huge reduction in its carbon footprint because there is no metal to melt.
Also, in comparison to die casting, the tool cost is 50% less and the tool life is 5-10 times greater. The first block that CC is casting for the performance engine market is an after-market specialty engine, which can be an alternate to the popular Ford Duratec/Mazda MZR inline 4. The carbon fiber composite block weighs 20# (9.1 kilos) LESS than the stock alloy block.
Looking further forward, an entire range of 4- and 8- cylinder engine blocks is planned for motorsports as well as OEM automotive, truck and marine applications.