Methods for forming class-A components with moldable carbon fiber

A method for manufacturing a vehicle, the method comprising:

• fabricating a Class-A component (CAC), the method comprising:
• disposing a molding precursor within a die, wherein the molding precursor includes:
• a first skin layer comprising a first polymer matrix and a first fiber reinforcing material embedded within the first polymer matrix,
• a second skin layer comprising a second polymer matrix and a second fiber reinforcing material embedded within the second polymer matrix, and defined by an outer surface and an inner surface oriented towards the first skin layer,
• a third layer disposed between the first and second skin layers and comprising a third polymer matrix and a filler material interspersed within the third polymer matrix,
• wherein the first fiber reinforcing material and the second fiber reinforcing material each comprise a plurality of aligned carbon fibers defining a major axis and a second axis perpendicular to the major axis, and the plurality of aligned carbon fibers comprise a plurality of low strength regions staggered with respect to the second axis;
• compression molding the molding precursor in the die, wherein the die includes a punch and a block, and during compression molding the punch is configured to contact the second skin layer and the block is configured to contact the first skin layer;
• opening the die to create a gap between the punch and the outer surface of the second skin layer;
• and
• injecting a Class-A finish coat precursor into the gap to create a Class-A surface layer on the compression-molded molding precursor and form the CAC, wherein the Class-A finish coat precursor includes conductive carbon and one or more of a polyurethane, an epoxy, a polyester, and a vinyl ester;
• painting the CAC;
• and
• integrating the painted CAC with a rigid vehicle frame.