Originally developed for aerospace and perfected in high-level motorsport, carbon fibre has long been valued for its incredible strength-to-weight ratio. In Formula 1 and other racing categories, it became the go-to material for reducing weight while maintaining rigidity and safety—an innovation that soon found its way into road cars and the aftermarket scene.
Today, carbon fibre car parts are a popular upgrade for drivers seeking lightweight strength, visual appeal, and premium quality. Whether it's actual body panels, a front splitter, a rear spoiler or mirror caps, carbon fibre offers a sleek, high-performance look that sets vehicles apart. But how are these parts actually made?
In this blog, we explore the full carbon fibre manufacturing process—from raw materials to the finished product—with a spotlight on MHC LDN, a leading UK manufacturer of carbon fibre parts known for their exceptional craftsmanship, flawless fitment, and commitment to quality, MHC LDN sets the standard in the carbon fibre aftermarket. Let’s take a closer look at how their parts are brought to life.
What Is Carbon Fibre and Why Is It Used in Cars?
Carbon fibre is a high-strength, lightweight composite material made from thin strands of carbon woven together and bonded with resin. Known for its impressive rigidity and minimal weight, it’s used extensively in automotive design to enhance both performance and aesthetics.
In road cars, carbon fibre is especially popular for exterior styling upgrades such as spoilers, diffusers, splitters, and mirror covers. By replacing heavier plastic or metal parts, carbon fibre helps reduce overall vehicle weight—improving acceleration, handling, and efficiency. Like lots of motorsport technology, carbon fibre has 'trickled down' into high-performance street cars and is seen as an attractive and premium material by buyers.
We built our name by supplying high-quality carbon fibre accessories for a range of BMW models, then branching out to other brands such as Audi, Toyota and Tesla. But as we grew larger, we needed to find a reliable manufacturer of automotive carbon fibre - this is where MHC LDN came in.
At MHC LDN, carbon fibre isn’t just about looks—it’s about precision, durability, and craftsmanship. Every component is engineered to deliver a perfect fit and a refined finish, enhancing the overall driving experience while maintaining long-term reliability. The longevity of MHC's carbon is unrivalled - we will touch on their manufacturing techniques shortly so you can see just how complex the process is and why carbon fibre is more expensive than other automotive materials such as steel, aluminium and ABS.
What Materials are Used in Carbon Fibre Manufacturing?
The quality of any carbon fibre part begins with the materials used. Carbon fibre fabric comes in different weaves and is bonded using resin to create a solid, durable structure. However, the manufacturing method—whether wet-laid or pre-preg—can greatly influence the final product’s strength, finish, and precision.
Wet-Laid Carbon Fibre
Wet-laid carbon fibre involves manually applying resin to dry carbon fabric laid in a mould. While this method is more cost-effective and widely used, it can result in slightly heavier parts and less consistency if not executed with care. It requires careful attention to achieve an even resin distribution and to remove any trapped air bubbles, which can affect surface quality.
Pre-Preg Carbon Fibre
Pre-preg carbon fibre—short for "pre-impregnated"—comes with the resin already infused into the fabric at a precise ratio. The material is stored cold and cured under heat and pressure, usually in an autoclave or oven. This process produces stronger, lighter, and more visually flawless parts with greater consistency. The result is a premium finish and excellent structural integrity, making pre-preg the gold standard for high-end applications.
MHC LDN takes manufacturing a step further by using precision-engineered aluminium moulds instead of fibreglass or epoxy moulds. Aluminium moulds allow for tighter tolerances, which results in exceptional part accuracy and fitment—a key priority for vehicle owners who demand factory-like alignment. This attention to detail helps ensure every MHC carbon fibre component fits perfectly out of the box, with no compromise on finish or durability.
Wet Laid Vs Pre-Preg Carbon Fibre:
How Are Carbon Fibre Car Parts Made?
At MHC LDN, every carbon fibre part is built with precision, from the very first design sketch to the final polish. The process begins with 3D scanning multiple vehicles, allowing the team to digitally replicate OEM bumpers and bodywork with extreme accuracy. These high-resolution scans are imported into specialised CAD software, where concept designs like the MHC SP1 front splitter are brought to life using exact vehicle dimensions. This ensures every part is developed with a factory-level fit and finish in mind.
From the CAD data, bespoke aluminium moulds are created—an investment that can cost tens of thousands of pounds per design. Unlike cheaper fibreglass moulds, aluminium offers superior thermal stability and tighter tolerances, resulting in a higher-quality part with a flawless fit. Dry pre-preg carbon fibre sheets are then hand-laid into the moulds with precise alignment, ready for curing under controlled heat and pressure.
However, not every piece passes the test. During the first stage of quality control (QC1), any parts with visible weave flaws or heat-induced distortion are immediately rejected. Even if a part comes out structurally perfect, the clear lacquer coat must also meet strict standards. MHC LDN uses a specially developed lacquer engineered for carbon fibre, offering a deep gloss finish with outstanding UV and corrosion resistance. If the lacquer is uneven or reactive, those parts are removed during QC2.
The final quality control stage includes scratch testing, test-fitting, and hand-polishing. Only parts that pass every inspection are approved for customers—ensuring each product lives up to MHC LDN’s reputation for excellence in both fitment and finish.
Conclusion
Carbon fibre car parts offer more than just visual appeal—they represent a commitment to quality, performance, and precision engineering. From the early days of motorsport to today’s premium aftermarket upgrades, carbon fibre remains a symbol of innovation and excellence.
At MHC LDN, the process of creating carbon fibre parts is rooted in accuracy, craftsmanship, and an unwavering attention to detail. From 3D scanning and CAD design to the use of premium pre-preg materials and custom aluminium moulds, every step is designed to deliver the best possible fit and finish. With rigorous quality control at every stage and a specially formulated lacquer for lasting protection, MHC LDN parts are built to stand out—and to last.
Whether you're upgrading your vehicle with a front splitter, diffuser, or mirror caps, choosing MHC LDN means choosing parts that are engineered for perfection.
