Toray Industries has taken a significant step toward next-generation composite airframe manufacturing by successfully testing a thermal welding technology that enables rapid, high-strength bonding between thermoset and thermoplastic CFRP structures. The development directly addresses one of aerospace composites' most persistent bottlenecks — slow, complex joining processes driven by adhesive bonding and mechanical fastening.
By enabling direct welding between dissimilar CFRP systems, Toray's approach not only delivers higher joint strength than conventional adhesive methods but also reduces bonding cycle times by nearly threefold, positioning the technology as a productivity lever for high-rate composite aircraft programs while offering potential weight savings through reduced fastener dependency.
Thermoset CFRP is widely used for primary aircraft structures due to its excellent material properties and long track record of practical use. In recent years, as demands for smaller components and more complex geometries have grown, the use of thermoplastic CFRP — well suited for high-rate production and offering high design flexibility — has also expanded. By combining thermoset and thermoplastic CFRP, there are anticipations for new airframes with enhanced performance and productivity.
Toray drew on years of expertise in CFRP intermediate material (prepreg) manufacturing and in CFRP molding and processing to develop this thermal welding technology. It delivers higher bonding strength than conventional adhesive bonding and makes bonding for simulated aircraft structures three times faster than conventional adhesive bonding and bolted fastening. The technology can also lower aircraft weight by reducing the number of bolt fasteners.
Going forward, Toray will accelerate its commercialization efforts in collaboration with aerospace manufacturers. This technology is the result of the Development of New Innovative Composite Materials and Forming Technologies, supported by the New Energy and Industrial Technology Development Organization (NEDO).
Source: www.toray.com
