2/2 TwillBecause of the complex and intricate contours required in sunglasses design, we typically use a 2/2 Twill weave carbon cloth (shown at right). This allows the cloth to drape the moulds, and press into the tighter areas. It looks great and has more of a 'diagonal' pattern when viewed in the light.
PlainPlain weave is the next most popular pattern we use. It gives more of a 'checkerboard' pattern, and a tighter weave that is harder to drape and fit into tight contours, but aesthetics are great.
We're pushing the limits of sunglasses design. Instead of solid injection moulding, or thick flat sheet CNC milling of the sunglasses frames and arms, we wanted to utilise a hollow-core, stressed-skin design.
Carbon fibre products start life as two separate materials: the carbon fibre cloth, and the epoxy. While they remain separate they are weak, but bringing them together they form a whole composite material that is stronger than the sum of the two components.
It is this synergy of carbon fibre with the epoxy matrix that allows us to take advantage of the hollow-core design. Technically referred to as a 'monocoque', it is used in high performance jet aircraft and Formula 1 chassis. From experience, a stiffer, stronger structure can be achieved for the same or at a much reduced weight.