Composite Free Floating Rail system?

[cptm4]

I would like to know why Free floating rail are made by expensive material like Aluminum?

Is it possible to redesign the AR free floating rail using composite material?

The requirements of composite free floating rail

1. Extremely light weight
2. Harder than Aluminum alloy.
3. Possibility of injecting color into the manufacturing process, hence scratch proof.
4. 100% not bendable, extreme rigid.
5. Very low heat conductivity
6. Very Low electricity conductivity
7. Durable and reliable
8. Cheaper than conventional Aluminum rail systems.

[SteveL]

There are some available made of carbon fiber. Is that not what you want?

ETA: I think they're all only available in black though.

[cptm4]

There are some available made of carbon fiber. Is that not what you want?

ETA: I think they're all only available in black though.

I was wondering why composite free floating rails are not as common as aluminum free floating rails?

[An Undocumented Worker]

I was wondering why composite free floating rails are not as common as aluminum free floating rails?

Come up with a great design, patent it, find someone to manufacture it, and have all the money you'd ever want for ammo.

[rob_s]

Biggest reason? At some point it has to integrate with metal, and that joint historically becomes a problem. The first carbon fiber BMX bikes ALWAYS failed as the pipe ends where they transitioned into metal.

On the AR handguard at some point you have to have a metal nut. how you join the composite to the metal is the weak point in the system. The old carbon fiber tube handguards weighed more than a 4-rail aluminum system because of that big-ass nut.

[NotDylan]

Honestly, I'm surprised we haven't seen polymer rails yet that are molded around metal frames similar to handguns.

[Jaysop]

That would actually be a great idea. Something purpose built.
If the nut has to be aluminum couldn't the receiving threads on the rail be incorporated as a solid pieces of rod like aluminum running the whole length of the rail kind of like rebar in concrete?(like dylan said)
It would have added weight from that but the overall weight would be much lighter.
maybe I just dont know but id buy something like that, I hate heavy rails.

[Stickman]

Honestly, I'm surprised we haven't seen polymer rails yet that are molded around metal frames similar to handguns.

Something like the ARMS SIR?

[cptm4]

My reasoning is: US marines have been using polymer non free floating handguard since 60', I simply ask why not composite free floating handguard.

[cptm4]

You made a valid point. I want to points out that carbon fiber is simply one of many many many composite materials. There are many amazing new composite materials (PlumCrazy composite lower come to mind) would be perfect for this purpose.

As for the joint issue, why not design a aluminum cup that would encapsulate one end of the composite rail, the aluminum cup would be function as a reinforced bridge between the receiver and the composite rail. It could be even design in a way that the aluminum cup simple secure the composite rail in place using nothing but pressure, friction or other means without the needs of any screw holes on the composite rail system.

Nowadays we see all rail systems are based on a simple one piece design made by a single material of Aluminum alloy. I think why not a more complex design that would utilize both Aluminum and composite materials to create a rail system that could achieve the best of both world (with the properties I mentioned in the first post).

Biggest reason? At some point it has to integrate with metal, and that joint historically becomes a problem. The first carbon fiber BMX bikes ALWAYS failed as the pipe ends where they transitioned into metal.

On the AR handguard at some point you have to have a metal nut. how you join the composite to the metal is the weak point in the system. The old carbon fiber tube handguards weighed more than a 4-rail aluminum system because of that big-ass nut.