Development of Precursor Polymeric Fibers Enabling a New Carbon Fiber Manufacturing Process

Carbon fiber reinforced plastics (CFRPs) are utilized in aerospace, transportation, renewable energy, and other advanced applications owing to their exceptional specific strength and stiffness. However, the widespread adoption of carbon fiber remains limited by its high manufacturing cost, which is largely associated with the energy-intensive stabilization process required for conventional polyacrylonitrile (PAN)-based precursor fibers.

To address this challenge, extensive efforts have been devoted worldwide to developing alternative precursor materials. Nevertheless, many of these approaches face significant obstacles in scalability, processability, and the ability to produce carbon fibers with competitive mechanical properties. In Japan, an alternative strategy has emerged that focuses on the development of novel precursor polymeric fibers capable of fundamentally transforming the carbon fiber manufacturing process itself.

This presentation introduces recent advances in precursor polymer design aimed at enabling new carbon fiber manufacturing routes with significantly reduced energy consumption. Particular attention will be given to rigid and linear aromatic polymer systems that exhibit unique thermal conversion behavior, potentially eliminating or substantially shortening the conventional stabilization process. The relationship between molecular structure, fiber formation, thermal conversion mechanisms, and resulting carbon fiber properties will be discussed.

Furthermore, recent progress achieved through national collaborative programs involving universities, industrial partners, and research institutes will be presented. These efforts are establishing a new paradigm for carbon fiber manufacturing that combines material innovation with process innovation. The proposed approach offers a promising pathway toward sustainable and economically viable carbon fiber production while maintaining the high performance required for future structural applications.