Carbon fiber to go mainstream in automotive by 2025

Driven by a faster-than-expected pace of technological development, carbon-fiber reinforced plastics (CFRPs) will be poised to gain widespread adoption for automotive lightweighting by 2025, according to a study by analyst firm Lux Research (Boston, MA).

By 2025, use of carbon fiber composite plastics is forecast to move beyond high-end vehicles. The part shown here is a  roof assembly for the Dodge SRT Viper processed by Plasan Carbon Composites using a carbon fiber weave prepreg from Cytec Industries and a unidirectional carbon fiber prepreg from Toray Carbon Fibers America.

Advances underway in fiber, resin and composite part production will reportedly lead to a $6 billion market for automotive CFRPs in 2020, more than double Lux's earlier projection. Even this figure is dwarfed by the full potential for CFRPs in automotive if they can become affordable enough for use in mainstream vehicles according to the firm.

"Current trends strongly indicate significant mainstream automotive adoption of CFRPs in the mid-2020s, and companies throughout the value chain must position themselves to take advantage of the coming shifts. However, long-term megatrends towards urbanization, connectivity and automation suggest that there could be a limited time window beyond that for penetrating the automotive space," said Anthony Vicari, Lux Research Associate and the lead author of the report entitled Scaling Up Carbon Fiber: Roadmap to Automotive Adoption. "CFRP developers will have to continue the pace of innovation to overcome the high cost that has so far limited the material to less price-sensitive markets like aerospace and sporting goods," he added.

Lux Research analysts reviewed the technology development in CFRPs, and evaluated its economics to consider its impact on the automotive sector. Among their findings:

  • Growing partnerships hasten development. The number of direct partnerships between automakers or Tier-1 automotive suppliers and carbon fiber players has nearly doubled to 11 since 2012. Toray Industries (Tokyo), with partnerships with Plasan Carbon Composites (Grand Rapids, MI) and Magna, has formed the most new relationships and is a major hub.
  • Patent uptick suggests mid-2020 adoption. Using a predictive tool, Lux Research identified a lag of about 18 years between uptick of patent activity and attainment of mainstream commercial adoption milestones. With another major upturn in CFRP patent activity occurring in 2007, large-scale mainstream automotive use is likely by the mid-2020s.
  • Other manufacturing costs need to be cut. Carbon fiber itself, at $28/kg for standard modulus fiber, represents just 22% of the cost of a final CFRP part. Additional advances are needed to reduce capital, labor, energy, resin and processing costs, which together make up the remaining 78%.


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