Mars Materials, Inc., a public benefit corporation working to store captured carbon dioxide into everyday products, announced a major manufacturing breakthrough. Working with textile experts at The Textile Innovation Engine of North Carolina and North Carolina State University (NC State), Mars Materials has successfully turned its CO₂-derived product into a high-quality raw material for making carbon fiber.

The joint study proved that Mars Materials carbon negative product works exactly like the traditional chemical today made from oil and coal. In its very first test, the product met the strict standards needed for high-performance carbon fiber: the kind used in airplanes, transmission lines and cars.

This newly announced breakthrough marks a potentially disruptive moment for the advanced composites industry. By converting captured carbon dioxide into a viable carbon fiber precursor, the development directly targets one of the most critical inputs in high-performance composite structures. Carbon fiber remains the backbone of aerospace-grade composites used in fighter jets, space systems, and next-generation platforms, and any shift in how this reinforcement material is produced carries implications for cost structures, supply security, and long-term scalability across the global composites value chain.

"This result keeps a promise we made to our investors and the industry," said Aaron Fitzgerald, CEO and Co-Founder of Mars Materials. "We proved we can make carbon fiber from the air without losing any quality. Just as we did with our water-soluble polymers, getting it right on the first try allows us to move faster. We can now focus on scaling up production to accelerate bringing manufacturing of this critical material back to the U.S."

How They Proved It

The testing was done by Dr. Januka Budhathoki-Uprety and her research team at the NC State Wilson College of Textiles. Researchers took Mars Materials product, called Hoigen-C, and turned it into polyacrylonitrile (PAN), the sole ingredient for carbon fiber. They tested it and found it was chemically identical to the version made from oil and coal.

"The chemical structure and molecular weight are similar to commercial PAN," said Dr. Ericka Ford, Associate Professor at NC State. "It is definitely a drop-in because you can add in any co-monomer that you want. For carbon fiber manufacturers looking to reduce their carbon footprint, this validates a viable pathway."

This validation opens a critical domestic supply line for major carbon fiber buyers like the United States military, who use the material in key applications for warfare. The old, polluting way of making carbon fiber relies on a volatile global supply chain and creates toxic waste. Mars Materials way to PAN uses captured CO₂, is hydrogen cyanide free and ensures a secure North American supply chain.

With the chemistry solved, the focus now shifts to spinning fiber and planning for mass production. Interested commercial partners and funders should contact Mars Materials to discuss partnerships.