From carbon fabric to the finished performance roof box
On Instagram, you usually just see the finished product in the end.
A GT3 RS.
A Ferrari in the snow.
Or a Lamborghini with a roof box in St. Moritz.
However, the vast majority of the work happens beforehand.
In our own fiber-composite production facility in Germany.
Since bringing production back in-house, we control a significantly larger share of the value chain directly.
Why we brought production back in-house
To us, a performance roof box is not an anonymous mass-produced item.
Surface quality, fit, weight, finish, and custom client requests play a crucial role.
The further away production is from your own team, the harder it is to maintain this level of control.
That is why we have once again set up our own fiber-reinforced composite production facility.
This allows development and production to work in closer collaboration.
Whenever we identify a potential improvement on a vehicle, the feedback goes straight back to the production floor.
This shortens the path from initial concept to physical component and the road.
Step 1: Material and layup preparation
A carbon shell does not start out as a finished black surface.
The fiber layers must be prepared and positioned in accordance with the component structure.
The visual appearance of the weave is only one factor in this equation.
Fiber orientation, overlap areas, and structural design all directly impact the final component.
Particularly with exposed carbon fiber, aesthetic standards are exceptionally high.
Step 2: Lamination
The prepared carbon layers are placed into the mold and built up into a fiber composite.
This phase of the process demands precision and composure.
A minor imperfection can later become glaringly obvious on an exposed surface.
Therefore, manual craftsmanship here is not just a romanticized marketing term.
It is an essential part of the process.
The finished component begins with meticulous work inside the mold.
Step 3: Curing and tempering
Following lamination, the fiber composite must undergo a defined curing process.
To achieve this, we utilize our specialized oven technology and controlled temperature profiles.
The exact sequence depends on the resin system used and the specific component architecture.
The critical factor is that the material not only looks exceptional, but also delivers its intended mechanical properties.
Step 4: Demolding and quality control
Following the curing process comes one of the most thrilling moments.
The shell is demolded from the tooling.
The true surface finish is now revealed.
We inspect the component for any visual or functional imperfections and determine the necessary finishing steps.
Exposed carbon fiber leaves little room for error.
Step 5: Finishing and Painting
Not every ASPHALTKIND roof box is finished in exposed carbon fiber.
Many customers request gloss black, matte black, or custom body-color matching.
Others prefer a combination of carbon fiber and paint.
Particularly for custom-configured sports cars, this step becomes an integral part of the vehicle design.
PTS paint, brake calipers, wheels, or existing livery can be incorporated into the roof box concept.
Step 6: Hardware, Locking System, and Assembly
Two carbon shells only become a fully functional roof box once the mechanical components are integrated.
Hinges, latches, interior trim, and other components must be meticulously installed and adjusted.
Depending on the specification, additional customizations are applied.
The respective carrier system is also an integral part of the overall product.
An exquisite carbon shell alone does not constitute a performance roof box.
Why every roof box is uniquely distinct
Our production volumes are intentionally far removed from industrial mass manufacturing.
This allows us to accommodate bespoke customer requests.
At the same time, it means that every component passes through many expert hands.
Precisely this combination of low-volume production and engineering defines our brand identity.
We do not build products for the anonymous average.
We engineer roof boxes for specific vehicles and discerning clients.
Frequently asked questions about carbon roof box manufacturing
Where are ASPHALTKIND roof boxes manufactured?
We manufacture the carbon fiber components in our own fiber-composite production facility in Germany.
Is every roof box handmade?
A significant portion of the fiber-composite production, finishing, and assembly is done by hand.
Can every roof box be custom-painted?
Yes. Depending on customer preference, exposed carbon fiber, exterior vehicle color, gloss black, and custom design variants are available.
Why is exposed carbon fiber labor-intensive?
Because in addition to structural quality, the fiber weave and surface finish must remain visible. Imperfections cannot simply be concealed under an opaque paint coat.
Built in Germany. Driven everywhere.
Nevertheless, the most important moment does not take place in the workshop.
It happens on the road.
When carbon fiber, resin, hardware, and many hours of labor transform into a roof box that travels with a customer to St. Moritz, Monaco, or a track day.
That is precisely what we build for.