As a material for structural and functional components, CFRT thermoplastic laminates can replace metals and traditional thermosetting composites in multiple areas (e.g., underbody protection, body panels, interior parts), achieving overall weight reduction.
In the next decade, short-range electric vertical take-off and landing (eVTOL) aircraft are expected to become widespread in cities. They impose extremely high requirements on structural materials: not only lightweight, but also high strength, high toughness, and recyclability. The high specific strength and reprocessable properties of CFRT align perfectly with these needs.
The operating speeds of high-speed trains and maglev trains continue to increase, placing more stringent demands on the aerodynamic design and weight reduction of vehicle bodies. CFRT laminates are not only lightweight but also exhibit excellent flame-retardant performance (meeting standards such as EN 45545), making them suitable for vehicle exteriors and interiors.
The continuous fiber-reinforced structure endows CFRT laminates with exceptional mechanical properties: their specific strength is more than 5 times that of steel, and their specific stiffness is significantly superior to aluminum alloys. This means CFRT can achieve substantial weight reduction while meeting the same strength requirements.
The thermoplastic matrix of CFRT allows the material to be rapidly formed after heating, with a molding cycle of only tens of seconds to a few minutes—far shorter than the long curing time required for thermosetting composites. This enables large-scale production of transportation components.
During high-speed driving or flight, materials must withstand sudden impacts and fatigue loads. While maintaining high strength, CFRT laminates possess high fracture toughness and impact resistance, making them suitable for use in safety-critical components.
From a full-lifecycle perspective, the recyclability of CFRT adds a sustainable dimension to lightweight design: it not only reduces energy consumption and emissions during the usage phase but also integrates into recycling systems after decommissioning.
CFRT laminates can achieve structural and functional integration through thermoforming, local thickening, and embedding of functional components. This allows designers to merge multiple parts into a single composite structure, reducing assembly steps and the number of fasteners for further weight reduction.
The moldability of CFRT makes it easy to manufacture components with complex curved surfaces, such as car roofs, train noses, and aircraft wings. Such optimization not only improves appearance but also reduces wind resistance, indirectly enhancing energy efficiency.
By adjusting fiber laying directions and thickness, local performance can be enhanced in key stress areas, maximizing material utilization. This "on-demand reinforcement" approach stands in stark contrast to the overall thickening of traditional metals.
A European EV manufacturer used CFRT thermoplastic laminates to replace aluminum alloys in battery trays, achieving a 35% weight reduction while improving collision resistance and fire safety. The molding cycle was shortened to 2 minutes, increasing production efficiency by 40%.
An Asian rail transit manufacturer applied CFRT laminates to high-speed train seat backrests and roof interiors, reducing carriage weight by 300 kg. Annual energy savings were equivalent to a reduction of 25 tons of carbon dioxide emissions.
An American urban air mobility company used CFRT laminates in the wing and cabin structures of eVTOL aircraft. This not only met flight load and safety standards but also achieved a 95% recyclability rate for components.
- Reduced raw material consumption
- Shortened processing time
- Improved yield rate
- Energy conservation (fuel or electricity)
- Enhanced load capacity and range
- Lower maintenance costs
- Realized material recycling and reuse
- Reduced waste disposal costs
- Created secondary raw material revenue for enterprises
CFRT laminates can be integrated with solid-state batteries and hydrogen fuel cell energy storage systems, enabling the fusion of structural components and energy systems to save space and weight.
Sensors can be embedded in CFRT laminates to enable real-time monitoring of structural health, ensuring safe operation.
Future CFRT molding will be deeply integrated with automated production lines, robotic arms, and digital twin technology, realizing full-process intelligence from design to finished products.
CFRT thermoplastic laminates are not merely a material choice for lightweight design—they are the technical core of structural innovation in future transportation. Combining high performance, sustainability, and manufacturing efficiency, they can provide systematic solutions for automobiles, rail transit, aerospace, and new mobility tools amid the trends of electrification, intelligentization, and low-carbonization.
