Forged carbon is a case material made by pressing short, randomly placed carbon fibres in a heated mould. It matters because cases come out nearly finished and almost no material is wasted. The surface shows random light and dark patches in blacks and greys, a bit like camouflage.
How is forged carbon made?
The method works much like metal stamping. Carbon fibre is cut into short pieces of about 4 to 5 cm. Bundles of these chopped fibres are scattered at random into a female mould cavity made of steel. A male mould then presses down on them with several tons of force. The fibre is chosen so that it already holds the right mix of carbon and resin. The case comes out of the heated press nearly finished. Only a little milling is needed, for screws, strap fittings and a few other spots.
How is it different from woven carbon fibre?
In woven carbon fibre, the fibres line up in a fabric. Forged carbon uses short, loose pieces instead, scattered at random in the mould. So there is no regular weave to see. The two also differ in waste. The usual layup method for layered carbon can waste up to a fifth of the material. Forging carbon wastes almost none.
Where it comes from
Audemars Piguet says it was the first watch brand to bring forged carbon into watchmaking, in 2007. Its use of the material grew out of a meeting with Vincent Duqueine, who ran the French company that held the technology. The first forged carbon watch case arrived with the Royal Oak Offshore Alinghi Team model. The name reflects how closely the process resembles the forging of metals. After five years of research and development, the brand brought out a new kind that can be coloured. Audemars Piguet says this material, CFT carbon, has no pores and stands up well to moisture, heat and knocks.
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