Toray Carbon Fibre and Thermoplastic Pellet Advances Poised to Enhance Molded Product Cost Performances


Toray Industries, Inc., announced today that it has created a high tensile modulus carbon fibre and thermoplastic pellets that are ideal for injection moulding employing that fibre. The pellets will enable the efficient production of complex, rigid parts that are also light, thereby lowering environmental impact. These advances could greatly enhance cost performance. 

Toray will push ahead with research and development to commercialise the fibre and pellets within the next three years. 

Toray markets the TORAYCA® T series of high-strength carbon fibres for pressure vessel, automotive, and other industrial applications, as well as for aerospace. In 2014, it launched the TORAYCA T1100G carbon fibre, which offers a world-leading tensile strength of 7.0 GPa and a tensile modulus of elasticity of 320 GPa. 

In 2018, the company further expanded the potential of carbon fibre for high-end sports equipment and aerospace structural materials by commercialising TORAYCA M40X. This offering employs proprietary nano-level fibre structure control technology to balance a high compression strength and a tensile strength of 5.7 GPa, with a tensile modulus of 377 GPa. The fibre’s diameter of 5 microns constrains productivity, however, making costs an issue. 

In the development effort announced today, Toray tackled that challenge by pursuing further advances with its TORAYCA MX series control technology to create 7-micron fibres with uniform internal structures. The result was a fibre with a tensile modulus of elasticity of 390 GPa, around 70% higher than the standard level of TORAYCA series offerings for industrial applications, delivering a much better cost performance. 

TORAYCA thermoplastic pellets incorporating the newly developed carbon fibers maintain longer fibres than conventional high tensile modulus offerings after molding processes. The pellets can thus deliver attain a tensile modulus of 41 GPa. That is comparable to the 45 GPa of magnesium alloys. At the same time pellets have a specific gravity of just 1.4, against the 1.8 of magnesium alloy. Using these pellets to make complex parts through injection moulding processes would significantly enhance productivity and contribute much to lightening parts. 

Toray looks to cultivate diverse applications for its advanced pellets, including for parts in lightweight next-generation automobiles and in industry in general. 

The Toray Group is committed to delivering innovative technologies and advanced materials that provide the world with real solutions to the challenge of balancing development and sustainability. The new carbon fibre should contribute to the Group’s vision of balancing greenhouse gas emissions and absorption worldwide through the use of parts that are lighter and more energy efficient. Toray will contribute to society by creating new value through its drive to enhance the performance of TORAYCA carbon fibre and pellets and production processes.

Comparisons of basic properties of carbon fibre, molding processes, and tensile moduli of materials

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