CICC | New Energy Materials Series: Domestic Production of Large-Tow Carbon Fiber Is Within Reach

Carbon fiber is generally classified into two categories—large-tow and small-tow—based on filament count. Naming convention typically uses the ratio of the number of filaments in a tow to 1,000; for example, '1K' denotes a tow containing 1,000 filaments. Large-tow carbon fiber generally refers to products with filament counts of 48K or higher (the threshold was originally 24K but has since been raised as tow sizes increased). Common large-tow variants include 48K, 50K, 60K, 75K, 80K, 120K, 240K, and 480K, primarily applied in wind power, energy, civil engineering and construction, and transportation. Small-tow carbon fiber includes products such as 1K, 3K, 6K, 12K, and 24K, mainly used in specialized equipment, sports goods, and fishing gear. Production Process Precursor fibers constitute the critical technological bottleneck for manufacturing high-quality carbon fiber. Precursor production involves polymerizing monomers—such as acrylonitrile—into a spinning dope, followed by fiber formation. Based on solvent selection, continuity of the polymerization process, and spinning methodology, precursor preparation can be categorized into several types: By solvent, common systems include DMSO (dimethyl sulfoxide), DMAc (N,N-dimethylacetamide), and NaSCN (sodium thiocyanate); by polymerization continuity, processes are divided into one-step and two-step methods—the latter adds a water-washing and filtration step to remove impurities and metal ions from the polymer; by spinning technique, methods include wet spinning and dry-jet wet spinning. Among these, selection and precise control of the spinning process are key to stable production of high-performance precursors. Low Cost vs. High Performance: Two Strategic Pathways in Carbon Fiber Development The global carbon fiber industry originated in the 1960s, beginning with laboratory-scale R&D. In 1960, Japanese scientist Akio Shindo invented a method for producing carbon fiber from polyacrylonitrile (PAN) fibers and secured the corresponding patent—laying the foundation for carbon fiber development over the next six decades. The 1970s were characterized by engineering-scale technology development and expansion into new application areas. Toray Industries of Japan leveraged its advanced PAN precursor technology and exchanged carbonization know-how with U.S.-based Union Carbide Corporation to develop high-performance PAN-based carbon fiber. The 1980s featured industrialization, product series diversification, and major application breakthroughs. Companies including Toray and Hexcel (U.S.) produced high-strength and high-modulus carbon fibers, raising tensile strength from 3.5 GPa to 5.5 GPa—propelling applications into a new era of high performance. The 1990s were marked by mergers and acquisitions and intense competition for market share. Carbon fiber entered a period of steady growth in the early 21st century; after 2010, application-driven demand surged dramatically, and industry consolidation accelerated further. In 2013, Toray acquired Zoltek—a U.S. company ranked third globally in carbon fiber production—raising Toray’s market share from 20% to 30%, thereby maintaining its dominant position. For China, prior to the 21st century, the carbon fiber industry remained largely domestic, technologically backward, and unable to compete internationally.

[In-Depth Analysis] Carbon Fiber: A Half-Century Material Comeback Story

This article traces China’s remarkable journey in domestic carbon fiber technology—from catching up, to breaking through, to achieving strategic breakthrough. When aerospace rockets soar skyward, domestically developed large passenger aircraft cruise the skies, next-generation fighter jets slice through clouds, and massive wind turbine blades rotate across open fields, they all rely on a critical material described as “light as human hair, stronger than steel”: carbon fiber—an inorganic polymeric fiber with over 90% carbon content. Few realize that, for decades, this material technology was tightly embargoed by Europe, the U.S., and Japan, with high-end grades effectively banned from export; China’s domestic industry once struggled severely. How did China break out from near-total technological void to become a globally pivotal player? This half-century-long breakthrough path embodies the most rigorous scientific perseverance in new materials development—and stands among the most inspiring success stories of ‘Made in China.’ I. Global Origins: From Laboratory Discovery to Western Monopoly 1. Technological Genesis: U.S. and Japanese Foundations; PAN Route Becomes Industry Standard (1950s–1980s) The earliest precursor of carbon fiber dates back to Thomas Edison’s carbon-filament incandescent lamp in 1879. However, limited by processing techniques and material structure, early carbon filaments exhibited poor performance and were quickly eclipsed by tungsten filaments, fading into obscurity. Modern carbon fiber truly emerged amid Cold War-era strategic competition. In the 1950s, fierce aerospace and defense rivalry between the U.S. and USSR created urgent demand for lightweight, high-strength structural materials—shifting carbon fiber research from serendipitous discovery to systematic development. In 1950, U.S.-based Union Carbide pioneered viscose-based carbon fiber, mainly for spacecraft thermal insulation—but its high cost and limited performance hindered mass adoption. The real turning point came in 1959, when Japanese scientist Akio Shindo discovered that polyacrylonitrile (PAN) could yield high-performance carbon fiber. A British research team subsequently optimized the oxidative stabilization and drawing process, paving the way for industrialization. In 1969, Toray integrated core technologies to successfully mass-produce copolymer PAN precursor, formally establishing the PAN-based route as the industry standard. Today, over 90% of global carbon fiber production still follows this pathway. In the 1970s, Toray achieved industrial-scale production of T300-grade carbon fiber, gradually building a comprehensive high-strength product portfolio. U.S.-based Hexcel and Germany’s SGL soon entered the market, marking the initial formation of the global carbon fiber industry. Yet technology and production capacity remained highly concentrated among a few firms, and high-end sectors were heavily fortified—heralding an era of quiet but deliberate technological containment targeting latecomer nations. 2. Escalating Barriers: The U.S.–Japan–Europe Iron Triangle of Restrictions (1990s–2010s) Over the following two decades, carbon fiber evolved continuously toward higher strength, higher modulus, lower cost, and greater scalability. Toray consistently led the industry, launching successive high-strength grades—including T700, T800, T1000, and T1100—as well as high-modulus variants such as M40J, M55J, M60J, and M70J. It accumulated over 12,000 patents spanning the entire value chain, erecting an almost insurmountable intellectual property barrier. To prevent technology diffusion, the U.S., Japan, and European countries jointly enforced a three-tiered embargo under the Wassenaar Arrangement—restricting exports of technology, equipment, and high-end products alike. High-performance carbon fiber was placed on strict export control lists.

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Nippon Carbide Industries plans to merge its US subsidiaries into Nippon Carbide Industries (USA), Inc. effective September 1, 2026, aiming to streamline operations and consolidate management resources.

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