We offer a comprehensive range of thermoset prepreg materials tailored for various sectors, including aerospace and defense, industrial applications, sports and recreation, and automotive. Our products utilize specially formulated epoxy and BMI resin systems, combined with TORAYCA® carbon fibers and other woven carbon or glass fibers to meet your specific requirements.
Product Advantages
Flexible Cure Methods: We offer a suite of materials with proven flexibility in curing and consistency in mechanical properties achieved by hand layup, out-of-autoclave (OOA), vacuum-bag-only (VBO), and compression molding.
High Performance: Our portfolio of aerospace-grade prepreg materials satisfy strength, impact resistance, and heat tolerance application requirements. These are engineered to withstand tough conditions, ensuring reliability and longevity.
Customizable Forms: Compatible with multiple applications, including hand layup, AFP, and ATL. Available in multiple widths and roll configurations.
Model material properties such as cure kinetics, heat capacity, and thermal conductivity with Convergent’s RAVEN Explorer cure simulation design tool.
Use RAVEN ExplorerPrepreg Systems for the Aerospace Market
We offer prepreg systems that meet the requirements of aerospace, defense, and space manufacturers for primary and secondary structures, including materials that are qualified to AMS and NCAMP specifications with publicly available design data. Details on the advantages of each system, as well as commonly available product formats, can be found in the product’s datasheet listed in the table below including toughened prepreg systems and fast cure prepreg.
Aerospace Prepreg Selector Guide| PREPREG SYSTEM | DESCRIPTION |
|---|---|
| A 250°F cure epoxy resin with a public AGATE database, the 2510 prepreg system is specifically formulated for out-of-autoclave (OOA) processing of aerospace primary structures. It has balanced mechanical properties and flexible curing capabilities. Commonly paired with T700-series standard modulus (SM) fibers. Our 2510 prepregs are well understood and widely used in general aviation structures. | |
| 2511 is a semi-toughened epoxy prepreg system that was specifically formulated for better processing when compared with 2510. Our 2511 resin system can provide good structural properties and very low void content when processed in a variety of methods, including vacuum bag only (VBO) and press molding. Commonly paired with T700-series standard modulus (SM) fibers. | |
| An epoxy resin with a cure temp range of 250°F to 350°F that is commonly paired with standard modulus (SM) fibers. Flexible processing and curing methods. Ideal for high-volume production, specifically aerospace and advanced air mobility (AAM) markets. | |
| 3900 series prepregs are highly-toughened 350°F (177°C) cure systems with a public CMH-17 database. This prepreg is available in a variety of configurations, including unidirectional tape for manual or automated tape laying applications, slit-tape-tow for automated fiber placement applications, and plain-weave carbon and glass fabrics. It is commonly paired with T800-series intermediate modulus (IM) fibers. Used extensively in commercial aircraft primary structures. | |
| The next-generation 3960 prepreg system demonstrates the next leap in high-performance aerospace materials. This system is a highly toughened, 350°F cure epoxy resin that has been optimized for increased performance and flexible curing. Commonly paired with T1100-series intermediate modulus plus (IM+) fibers, our strongest TORAYCA® fibers, this material is perfect for specialty aerospace applications where material performance is the highest priority, providing an optimal ratio of strength to modulus properties. | |
| Toughened bismaleimide (BMI) resin system for aircraft primary structures requiring enhanced strength and toughness in high service temperature environments up to 450°F. Maintains the familiar handling and flow characteristics of traditional epoxy prepregs. |
Prepreg Systems for Sports & Recreation, Automotive and Industrial Markets
G-series resins maintain the high manufacturing standards of our aerospace-grade resins, optimized for use in all industries. These resins have lower price points and high-quality surface finishes and are designed for high flow and quick cures, making it perfect for use in high-end sporting goods, automotive parts, and other industrial uses.
| PREPREG SYSTEM | DESCRIPTION |
|---|---|
| A toughened epoxy system with excellent flow properties and a flexible (250-300°F) cure temperature. Our G-78 prepregs are perfect for thin-walled tube structures like fishing rods, arrow shafts, and golf clubs. | |
| A rapid cure system (290°F for 20 minutes) that provides a high-quality class A finish and excels in automotive applications. | |
| A rapid cure system with enhanced fire resistance and a high-quality class A finish. Excellent for automotive applications. | |
| An all-around resin with a flexible (250-300°F) cure, high-temperature resistance, and easy layup. Our G-94 prepregs are widely used in a variety of applications including sports, outdoor, industrial, medical, and more. |
Frequently Asked Questions
Are your materials qualified to industry standards, and is design data publicly available?
Yes. Toray has aerospace prepreg systems that are qualified to AMS (Aerospace Material Specifications) and are supported by publicly available allowable databases. These qualifications and open-access databases streamline the certification process, reducing the need for costly in-house testing and helping customers achieve faster time-to-market.
How do Toray’s 250°F and 350°F cure systems differ in application and performance?
The choice between cure temperatures is typically driven by the end-use environment and tooling capabilities:
250°F Systems (2510, 2511, 2700): These are engineered for lower-energy processing and are the standard for general aviation. They allow for the use of lower-cost tooling and are optimized for Out-of-Autoclave (OOA) and Vacuum Bag Only (VBO) environments.
350°F Systems (2700, 3900, 3960): These are highly-toughened systems designed for primary aerospace structures. They provide superior resistance to impact and environmental factors, with 3960 offering the highest performance-to-weight ratio when paired with T1100 IM+ fibers.
Which prepreg system is best for transitioning from prototype to high-rate production?
The 2700 prepreg system is specifically designed for scalability. It features a flexible cure range (250°F–350°F) that allows manufacturers to start with hand layup and oven cures during the R&D phase, then transition to Automated Fiber Placement (AFP) or rapid press molding for high-volume production without changing the material system.
What resin systems are available for different temperature and performance needs?
We provide specialized thermoset systems designed for specific environments:
Epoxy Systems: The most versatile, ranging from highly-toughened aerospace systems to industrial grade prepreg systems with lower price points and high-quality surface finish.
BMI (Bismaleimide) Systems: Ideal for high-temperature environments (up to 450°F) where enhanced strength and toughness are required. The 4000 prepreg system maintain the same handling and flow characteristics of the traditional epoxy prepregs.
How does the G-series optimize production for automotive and industrial markets?
While maintaining the same manufacturing standards as our aerospace-grade resins, the G-series (G-78, G-83CM, G-85FR, G-94) focuses on industrial efficiency:
Flexible Cure Methods: Available prepreg systems that work well with autoclave, oven cure, or press molding processes.
Surface Quality: Engineered for class A finish through post cure, minimizing sanding and finishing times.
High Heat Tolerance: Offers systems with high Tg, allowing for high temperature part demolding, reducing cycle time. Materials works well with high temperature paint curing cycles.