Manufacturing Process of Carbon Arrows

Unidirectional Layering: First, carbon fiber tows are wrapped around the mandrel in a straight, parallel pattern. This layer provides the arrow’s core strength, resisting bending and tension during flight.

Cross-Directional and Helix Layering: To add torsional strength and impact durability, additional tows are wrapped at angles—usually 45° (cross-directional) or 15-30° (helix).

Calibrated Tension: CNC machines maintain constant tension on the tows as they’re wrapped, ensuring the fibers are tightly packed. Machines are calibrated to within ±1% of the target tension.

Heat and Pressure Application: The preform is placed inside a cylindrical mold and subjected to high temperatures (120-180°C) and pressure (500-1,000 psi). The heat activates the resin, causing it to flow and bond the carbon fibers together.

Density Optimization: Compression removes air bubbles from the resin-fiber matrix, increasing the arrow’s density and strength. A well-compressed shaft has a density of 1.7-1.9 g/cm³.

Custom Spine Tuning: By adjusting the pressure and mold size, manufacturers can fine-tune the arrow’s “spine” (stiffness).

Controlled Oven Curing: The compressed preform is moved to a precision oven for a curing cycle that lasts 30 minutes to 2 hours, depending on the resin type. The oven’s temperature is ramped up gradually (5-10°C per minute) to prevent resin cracking.

Cooling Phase: After curing, the mold is cooled slowly (at 2-3°C per minute) to room temperature. Rapid cooling can cause thermal stress, leading to warping.

Mandrel Extraction: Using a hydraulic or pneumatic press, the mandrel is gently pulled out of the cured carbon tube. The release agent ensures the mandrel slides out smoothly.

Cutting to Length: The long carbon tube (usually 1.5-2 meters) is cut into individual arrow shafts using a diamond-tipped saw. The saw is computer-guided to cut to exact lengths with a tolerance of ±0.005 inches.

Deburring and Smoothing: The cut ends of the shaft are sanded with fine-grit sandpaper (400-600 grit) to remove burrs and create a smooth, flat surface.

Straightness Testing: Each shaft is rolled on a precision flat surface while a laser sensor measures deviation. Shafts with more than 0.001 inches of bow are discarded.

Weight and Balance Testing: Shafts are weighed on a digital scale and checked for balance. Arrows in the same “set” must have a weight variation of no more than 2 grains and a balance variation of no more than 0.5 inches.

Strength and Impact Testing: Randomly selected shafts are subjected to bending tests and impact tests. Shafts that show permanent deformation or cracking are rejected.

Surface Coating: Shafts are coated with a clear polyurethane or epoxy finish to protect against scratches and moisture. Some manufacturers add a matte or glossy texture for grip.

Insert and Nock Installation: The “nock end” is drilled to fit a plastic or aluminum nock, which is glued in place. The “arrowhead end” has a threaded insert glued in to attach different arrowheads.

Spine Labeling: Each shaft is labeled with its spine rating and weight to help archers match the arrow to their bow’s poundage and draw length.