The brief

Analyst view

• Founded 1926 as Toyo Rayon, renamed Toray 1970; now a diversified materials maker.
• TORAYCA is 50% of global aerospace carbon fiber; primary supplier for Boeing 787.
• 16-year Boeing contract exceeds $8.6B; scaling output to support 10 aircraft per month.

Technical approach

As reported

Precursor

Acrylic polymer synthesis

Toray makes polyacrylonitrile precursor, the starting material for carbon fiber.

Carbonization

Thermal conversion to graphite

Oxidation in air (~200°C) then heating in nitrogen (~1,500°C) converts precursor to graphitic carbon.

Sizing and tow

Fiber treatment and bundling

Coated fibers wound into tows of thousands; sold as prepreg or dry tow.

Prepreg composites

Fiber pre-soaked in resin

TORAYCA prepreg: carbon fiber in aerospace epoxy; ready for layup and cure.

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