The global application of carbon fiber composites can be broadly divided into three stages: the nascent stage, the rapid development stage, and the high-speed expansion stage.
First Stage: The Nascent Stage
The carbon fiber composites industry began between the 1970s and 1980s. In 1971, Japan’s Toray Industries collaborated with the U.S.-based Union Carbide Corporation to produce T300 carbon fiber, achieving large-scale monthly production of 1 ton. Toray subsequently upgraded carbon fiber quality through successive generations—T300, T800, and T1000—and pioneered the integration of carbon fiber materials into sports equipment such as racquets, fishing rods, and golf clubs. In 1972, Toray launched its first commercial carbon fiber composite product line—fishing rods. Carbon fiber reduced these rods’ weight by approximately 50%, though they were relatively more expensive. Subsequently, carbon fiber golf clubs, tennis rackets, and bicycles produced in the U.S. and Japan received high market acclaim for their performance, propelling Toray to global prominence as the world’s largest carbon fiber manufacturer. However, CFRP applications were primarily confined to sports and leisure products at that time. 1975 marked the first turning point since the 1973 oil crisis, which created an urgent need to reduce aircraft weight for fuel efficiency. Aircraft manufacturers like Boeing and Airbus focused on using carbon fiber composites for secondary airframe structures that did not compromise flight safety. In 1980, Boeing elevated CFRP requirements for commercial aircraft manufacturing. By 1982, they began incorporating T300 into the Boeing 757, Boeing 767, and the Space Shuttle. CFRP thus entered engineering applications for aerospace structures, spanning both military and commercial aircraft. Mass production of CFRP in military aircraft manufacturing was achieved during this period.
Phase Two: Rapid Development Period
The 1990s to the 2000s ushered in the first wave of carbon fiber composite applications. In 1990, Boeing adopted Torayca’s CFRP prepregs for the primary fuselage structure of the Boeing 777, while U.S. aerospace company Hexcel acquired the carbon fiber division from Hercules. Amoco, a major U.S. carbon fiber manufacturer, joined forces with Union Carbide and established joint ventures with Toray and Celanese. In 2001, ownership of these assets changed hands and the company was renamed Cytec. In 1997, the pioneer in carbon fiber, Courtauld, disappeared from the scene when German graphite giant SGL Group acquired RK Carbon from the British firm. Later, the SGL Group acquired shares in carbon fiber through a joint venture with golf club manufacturer Aldila.
Boeing launched the 787 program in 2003, employing CFRP more extensively in the fuselage and primary structures than any previous commercial aircraft (accounting for 50% of the fuselage weight). CFRP usage expanded dramatically from being used only in the flaps of the Boeing 767 (accounting for 3% of the airframe weight) to covering the fuselage, main wings, tail surfaces, and flaps of the Boeing 787 (accounting for 50% of the airframe weight). Due to the extensive use of CFRP, aluminum usage decreased from 77% of the airframe weight to 20%. Compared to the Boeing 767, the Boeing 787 achieved significant weight reduction, resulting in fuel savings of 20%-22%. In 2005, Boeing’s 787 competitor Airbus launched the A350XWB program, which also primarily utilizes CFRP (53% of airframe weight). This reduced structural maintenance by 50% and lowered airframe inspection frequency (extending the Airbus A380’s required maintenance interval from 8 to 12 years). The Boeing 787 and Airbus A350 represent milestones with CFRP constituting 50% and 53% of their respective airframes. The surge in CFRP usage, particularly after 2005, stems primarily from airline demands for reduced fuel consumption, CO₂ emissions, and maintenance costs, extended design lifespans, and lower tooling and assembly expenses through component integration.
Phase Three: Period of Rapid Expansion
Since the early 21st century, carbon fiber applications have expanded dramatically from aerospace to non-aerospace sectors, characterized by high-volume, low-cost production. Faster growth trends have emerged in wind energy, automotive, rail transportation, and civil infrastructure industries. Carbon fiber composites are now widely used in wind power generation, automobiles, pressure vessels, construction, sports equipment, and other sectors.
In the wind power sector
Zoltek—the global leader in low-cost industrial-grade carbon fiber—began collaborating with wind turbine original equipment manufacturer (OEM) Vestas in 2007 to incorporate carbon fiber into American wind turbine blades. Compared to blades made from glass fiber reinforced polymer composites, the use of CFRP composites in 60-meter-long turbine blades is projected to reduce total blade weight by 38%, lower costs by 14%, and enhance capacity, power, density, and fatigue life. The successful implementation of pultruded carbon fiber reinforced wing beam caps in wind turbine blades created unprecedented demand for carbon fiber within Vestas, driving increasing integration within the carbon fiber industry. A landmark event was Toray’s acquisition of Zoltek in late 2014, which led to the convergence of the carbon fiber industrial and aerospace markets.
In the automotive industry
In 2010, BMW and SGL established a joint venture carbon fiber plant in the United States with a total annual production capacity of 9 tons, aiming to enhance carbon fiber supply for lightweighting in electric vehicles. The vehicle frame incorporates a hybrid design using aluminum and CFRP materials. The rear bumper crossbeam represents the automotive industry’s first bent pultruded CFRP component, contributing to increased frame stiffness and rear impact resistance.
In the pressure vessel sector
High-pressure gas storage containers represent one of the largest and fastest-growing markets for advanced composites, particularly filament-wound carbon fiber composites. Key end markets for CFRP pressure vessels include bulk transportation of compressed natural gas (CNG) products and fuel storage for passenger vehicles, buses, and trucks whose powertrains rely on CNG and hydrogen as alternatives to gasoline and diesel.
In the construction industry
Carbon fiber composites are primarily applied in building and bridge reinforcement, pipeline repair and maintenance, novel building components, bridge decks, cables, and beams. Within this sector, 80%-90% of carbon fiber composites are used for structural reinforcement and the restoration of aging infrastructure.
In the sports and leisure sector
Carbon fiber consumption for athletic applications reached an impressive 18.5 metric tons in 2021. Golf clubs and bicycles represent the largest consumption sectors, accounting for 27.6% and 24.4% of total sales respectively. Due to the COVID-19 pandemic, demand for team sports equipment like hockey sticks declined significantly, while demand for personal sports gear such as golf clubs, bicycles, and fishing rods increased.