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In collaboration with  (Lenni, Pa., U.S.), (Portland, Ore., U.S.), a company specializing in 3D printing, thermoforming, machining and engineering services, announces the launch of Aerolite, a thermoformable carbon fiber solution that aims to reduce production times and costs while maintaining high performance and aesthetics. An end-use manufacturing service, RapidMade works with companies to design and develop the Aerolite carbon fiber parts via a vacuum forming process.

Aerolite carbon fiber offers several advantage. According to RapidMade, thermoforming reduces traditional cure cycles from hours to just 2 minutes per part, achieving 97% faster production times. The automated process also eliminates labor-intensive hand layups, reducing labor and tooling expenses by 75%. Consistent quality parts are also possible — automated forming and CNC trimming ensures high repeatability, minimizing defects and scrap rates.

Aerolite is available in two grades, 15% and 30% infill, and two thicknesses, 1.5 mm (0.060") and 2.5 mm (0.100"). The material features tensile strengths up to 200 MPa and flexural strengths up to 253 MPa, offering manufacturers a materials that is reported to be seven times the stiffness of polycarbonate.

Ideal for industries such as automotive, aerospace, robotics and heavy industrial, Aerolite supports complex geometries and high customization while maintaining structural integrity. Design guidelines accommodate thermoforming-specific considerations, ensuring seamless integration into existing production workflows.

For technical specifications and design support, visit  or contact Micah Chaban at mchaban@rapidmade.com.