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High Strength Thermoset Carbon Fiber Woven Prepreg
Our thermoset carbon fiber prepreg uses epoxy resin system, featuring stable resin content, high strength and good drape. Widely used in aerospace, sports equipment and industrial reinforcement.
Thermoset carbon fiber prepreg is a semi-finished composite material made by pre-impregnating carbon fiber reinforcement (woven fabric or unidirectional tapes) with a precisely controlled amount of thermoset resin, most commonly epoxy. The resin is partially cured to a 'B-stage' state, which gives the material a flexible, tacky texture at room temperature so it can be easily cut, laid up and shaped onto molds. The final mechanical properties are achieved only after the material is cured under heat and pressure.
As a ready-to-mold intermediate, prepreg eliminates the messy steps of manually mixing resin and wetting fibers on site. It delivers consistent fiber-to-resin ratio, uniform fiber distribution and reproducible part quality, which is why it has become the standard material in aerospace, high-end sporting goods and precision industrial applications.
Our thermoset carbon fiber prepreg is manufactured from PAN-based T700-grade carbon fiber with an epoxy resin system, offering an excellent balance of high strength, high stiffness, low weight and good fatigue resistance. It is available in woven fabric form (plain and twill weave) as well as unidirectional (UD) tapes, with stable resin content and long usable life.
2. Key Features and Benefits
High Strength and High Modulus. Based on T700 PAN-based carbon fiber, the cured laminate delivers outstanding tensile strength and stiffness, enabling thinner, lighter structures without sacrificing performance.
Stable Resin Content. Resin content is controlled within 33% ± 2%, ensuring uniform fiber wetting and consistent mechanical properties from batch to batch.
Good Drape and Tack. The prepreg is soft and flexible at room temperature with moderate tack, making it easy to lay up on complex curved molds and multi-layer structures.
Excellent Surface Finish. The fine epoxy formulation provides smooth, void-free surfaces after curing, reducing post-processing such as sanding and painting.
Low Out-Time and Long Shelf Life. Designed with a balanced reactivity, the material offers practical handling time at room temperature and long storage life under refrigeration, reducing waste.
Low Shrinkage and Dimensional Stability. Cured parts show minimal shrinkage and warpage, ensuring accurate geometry and repeatable dimensions.
Corrosion and Chemical Resistance. Carbon fiber and cured epoxy provide excellent resistance to moisture, most solvents and many chemicals.
Consistent Quality. Every roll is inspected for fiber areal weight, resin content, tack, width and contamination before shipment, with COA (Certificate of Analysis) available.
Reinforcement. Our prepreg uses PAN-based T700-grade carbon fiber, the most widely used high-performance fiber in the industry, known for its excellent strength-to-weight ratio. Woven fabric constructions — including plain weave (balanced, stable, good for flat parts) and twill weave (more drapable, ideal for curved surfaces) — are available in 1K and 3K tow sizes. Unidirectional (UD) tapes are also offered for applications requiring maximum stiffness in one direction, such as drive shafts, spars and ribs.
Resin Matrix. The epoxy resin system is specially formulated for vacuum bag and autoclave curing. It provides good tack at room temperature for easy layup, low volatile content during cure, and a high-performance cured matrix with strong fiber-matrix adhesion, heat resistance and low moisture absorption.
5. Applications
Aerospace and Defense. Aircraft interior panels, structural reinforcements, fairings and UAV frames where weight reduction and high reliability are critical.
Sporting Goods. Bicycle frames and wheels, tennis and badminton rackets, golf club shafts, fishing rods, ski and snowboard cores, helmets and protective gear.
Automotive and Motorsport. Body panels, hoods, roofs, drive shafts, suspension arms and trim parts that benefit from weight saving and stiffness.
Industrial Equipment. Robot arms, printing rollers, textile machine parts, X-ray tables and other precision components requiring rigidity and low inertia.
Marine and Wind Energy. Boat hulls, masts, propellers, wind turbine blades and structural cores exposed to demanding environments.
Medical Equipment. Lightweight radiolucent parts such as imaging tables and braces where transparency to X-rays is an advantage.
6. Curing Process Guidance
Our thermoset carbon fiber prepreg is designed for standard vacuum bag molding and autoclave processing:
- Cut the prepreg to shape and lay up the plies in the required orientation (e.g. 0°/90°/±45°).
- Apply vacuum bag with release film, breather and vacuum sealant tape.
- Cure at the recommended temperature with a controlled ramp rate (typically 1–3°C/min), hold time of 1–2 hours, and pressure of 0.3–0.6 MPa in autoclave, or under vacuum pressure only for low-pressure grades.
- Cool down slowly below 60°C before demolding.
A full cure cycle chart and process parameters are provided with every order. Compression molding and hot-press processing are also supported for mass production.
7. Quality Control
Every batch is manufactured under a strict quality system with the following inspection points:
- Incoming fiber inspection: tensile testing and surface quality check.
- Resin formulation control: viscosity, reactivity and gel time tested before impregnation.
- In-line monitoring: resin content, fiber areal weight and width continuously checked during production.
- Final inspection: visual inspection for contamination, wrinkles, edge defects, plus random sampling for resin content and mechanical testing.
Each shipment can be accompanied by a Certificate of Analysis (COA) including resin content, fiber areal weight, width, length, moisture and storage information.
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