Earlier quoted context omitted.
My question is just... why? It's not like carbon fiber was any cheaper than just making the thing out of steel or titanium like literally every other submersible. It just doesn't make any sense. You have none of the weight penalties that exist in aviation, so the heavier and the thicker the better.
As I understood it, you do have a weight penalty for a sub. You need to get back up by powered movement, or down by it. You are limiting your dive time either way. They can’t use foam for flotation at that depth. There is a concrete like “synthetic foam” if you want unpowered rise to surface but it’s expensive. I read early on they wanted carbon to be light enough to get back up by releasing weights on powerloss. Fro…
The word you are looking for is "syntactic foam", which is an epoxy or other material typically with embedded hollow glass microspheres. This material is used for the buoyancy components of undersea vessels. It comes in a broad variety of densities and depth ratings. It is typically machined into shapes on the inside of the part fitting around the metallic components and on the outside the shape of the outer surface of the vessel. It is also somewhat expensive, more for higher depth ratings (on the scale of dozens to low thousands of dollars per cubic foot). Here's a product from one of the suppliers I worked with for more info [0]
Typically, the goal in designing the vessel is to account for the mass and buoyancy of the metal parts and design in the right final volume of syntactic foam so that the vessel is neutrally buoyant at the operating depths, and doesn't have to work to stay up or stay down.
For more moderate depths, there are also various structural foams, which use a variety of chemistries to achieve low densities and high compression strengths. These are also used in sandwich panel construction for composites (instead of honeycomb, and for the same effect), e.g., [1].
Source: I own & run a composites design & manufacturing shop which does work on, among other things aerospace and undersea projects.
[0] https://www.trelleborg.com/en/applied-technologies/products-...