Toray Industries announced that it has successfully completed its tests on a technology that bonds carbon fiber reinforced plastic (CFRP) aircraft mock-up structures almost three times faster than conventional approaches.

Aircraft mock-up structure made with Toray’s technology.

Challenge: Complex and slow production

Thermoset CFRP is widely used for primary aircraft structures due to its excellent material properties and long track record of practical use.

In recent years, as demands for smaller components and more complex geometries have grown, the use of thermoplastic CFRP, well‑suited for high‑rate production and offers high design flexibility, have also expanded.

By combining thermoset and thermoplastic CFRP, there are anticipations for new airframes with enhanced performance and productivity. However, such conventional techniques as adhesive bonding and bolted fastening add complexity and slow production, creating a strong need for bonding technologies that improve both productivity and reliability.

Solution: Toray’s thermal welding technology

Toray drew on years of expertise in CFRP intermediate material (prepreg) manufacturing and in CFRP molding and processing, to develop a thermal welding technology that bonds thermoset and thermoplastic CFRP.

This delivers higher bonding strength than conventional adhesive bonding. It also makes bonding for simulated aircraft structures three times faster than that needed for conventional adhesive bonding and bolted fastening. The technology can also lower aircraft weight by reducing the number of bolt fasteners.

Relative bonding strengths of thermosetting and thermoplastic CFRP.

Going forward, Toray will accelerate its commercialization efforts in collaboration with aerospace manufacturers.