Have you ever wondered how our carbon-fiber parts are made? Today, we’re taking you behind the scenes of our M2 (G87) splitter production. Every stage of the process reflects our commitment to exceptional craftsmanship—from precisely cutting the prepreg carbon-fiber fabric to carefully forming each piece in the mold and finishing it with a flawless polish. This dedication to detail is why we’re able to deliver OEM-level quality straight to you. People usually see the end result — that glossy, woven pattern catching sunlight on the car — but almost no one sees the hours, the discipline, and the quiet precision that go into building a carbon fiber element.
It all begins with a sheet of carbon-fiber prepreg fabric. The term “prepreg” stands for “pre-impregnated,” meaning the material has already been infused with a carefully measured amount of resin during its production. Instead of working with dry fabric and mixing resin by hand, the manufacturer receives a material that has the resin matrix and the carbon-fiber reinforcement perfectly combined in advance. Prepreg can be processed in several ways depending on the intended application. The most common techniques—vacuum bagging and autoclave curing—are used to achieve the exceptional quality and consistency found in our parts.
First step is cutting the patterns. The cutting table is covered with prepreg carbon fiber, ready to be digitally cut into precise future elements. A technician taps the screen to adjust the most optimised cutting layout, while a laser is responsible for sharp and clean cuts, making the process both fast and incredibly efficient. Once the patterns are cut, the real craftsmanship begins. With the mold prepared and released, the technicians start the layup process—a stage where precision and experience matter more than anything else.
Using rollers and hand tools, the technicians smooth the material into every contour, making sure there are no wrinkles, air pockets, or misaligned fibers. It’s a careful balance—firm enough to shape the carbon cleanly, but controlled enough to avoid stretching or distorting the weave.
As the layers build up, the part slowly takes shape inside the mold. The workers check each ply twice, adjusting edges, trimming excess material, and ensuring the fiber orientation matches the engineering design. By the final layer, the mold is a perfect cross-section of the finished component, meticulously laid by hand. This is where the craftsmanship truly shows—every curve followed, every corner reinforced, every fiber placed with intention. When the layup is complete, the part is ready for vacuum bagging and curing, but its quality has already been defined by the care and precision of the workers during this stage.
The bagged mold is then wheeled into the autoclave—a large pressurized oven designed for high-performance composites. When the door closes, the autoclave follows a precise heat and pressure cycle. As the temperature rises, the resin softens and flows; as pressure increases, the fibers consolidate into a dense, uniform structure. Hours later, the part emerges fully cured, rigid, and flawlessly shaped.
After cooling, the vacuum bag is removed to reveal a strong, lightweight carbon-fiber component—its weave crisp, its contours exact, and its quality ready for the next stage of finishing. Once the autoclave cycle finishes, the mold returns to the workshop carrying a fully cured carbon part. The technicians gently remove it, revealing the crisp weave beneath. The shape is there, but the edges are rough and still need refining. Trimming comes first. At the cutting table, a diamond-tipped blade follows the mold line, removing excess material and shaping the part with clean, precise cuts. In minutes, the raw piece begins to look like a finished component.
Next, under bright lights, the surface is inspected. Technicians smooth out small imperfections and lightly sand any rough spots, gradually bringing out the carbon’s deep, uniform pattern. From there, the part moves to the finishing booth. Layers of clearcoat are applied in smooth passes, each one enhancing the depth and richness of the weave. After curing, the part is polished to a glossy, mirror-like finish.
When the team steps back, the transformation is complete: what started as prepreg sheets is now a sleek, perfectly finished carbon-fiber component—ready for installation.
