Past, present and future prospective of global carbon fibre composite developments and applications

Carbon fibre and carbon fibre reinforced polymer matrix composites (CFRPs) are important lightweight materials for aerospace, automotive, rail transport, infrastructure, and renewable energy applications. This paper provides a comprehensive review on the history of carbon fibres and carbon fibre composites, the current global CFRPs consumption, and trends for future developments in the aerospace, wind turbine, automotive, pressure vessels, sports and leisure, and construction sectors. The history of carbon fibres and CFRPs is discussed over four representative periods including their early development (1950–60's), growth of carbon fibre composites industry (1970–80's), major adoption of carbon fibre composites (the first wave, 1990–2000's), and expanded use of carbon fibre composites (the second wave, 2010's and beyond). Despite a 37% decline of carbon fibre consumption in the aerospace industry in 2021 caused by COVID-19, the global CFRP demand was around 181 kt which more than doubled its value in 2014. There is tangible projected increase over the next five years and the demand for CFRPs is expected to reach 285 kt in 2025, mainly attributed from the fast expansion of non-aerospace industries such as the wind energy sector. Lower cost carbon fibres (e.g., large tow) and associated manufacturing technologies are continually evolving. Finally, the implications of emerging materials and manufacturing methods in conjunction with recycling and reuse for carbon fibre composites are discussed.