Toray Launches Fast-Cure Composite Material Designed for High-Rate Aerospace and Defense Manufacturing

Toray Composite Materials America, Inc. (Toray CMA) announces the launch of 3960-FC, a fast-cure variant of the high-performance, highly toughened 3960 prepreg system. Engineered for mission-critical aerospace and defense applications, this fast-cure system reduces cure time by up to 45% while maintaining the proven mechanical performance of the 3960 system.

As the aerospace industry enters a new era of large-scale production, driven by exceptionally high production rates for next-gen single-aisle commercial aircraft programs, advanced air mobility platforms, and new mission-critical, mass-produced defense systems, manufacturers require advanced composite materials that deliver both mechanical performance and processing efficiency. 3960-FC was developed to help OEMs and their supply chains meet these increasing build-rate requirements.

“Increased pressure is being placed on material suppliers to provide a structural material solution with production rates now higher than what manufacturers have historically supported,” said Jeff Cross, principal director of defense programs. “3960-FC accelerates manufacturing cycles while maintaining the mechanical and structural performance customers expect from our premier product, the 3960 prepreg system, by demonstrating equivalence with the material data in the 3960 NCAMP database.”

Designed for High-Rate Aerospace and Defense Manufacturing

Building on the material capability of 3960, 3960-FC delivers exceptional toughness, hot/wet performance, tensile strength, stiffness, and damage tolerance. The material is also highly compatible with a broad range of automated manufacturing technologies, including Automated Fiber Placement (AFP) and Automated Tape Laying (ATL), and traditional processing methods.

3960-FC Prepreg Sandwich Panel

Additionally, the fast-cure variant enhances prototype capabilities by enabling the use of lower-temperature tooling, which reduces tooling costs, while expanding vacuum-bag-only (VBO) processing windows. The material is also capable of compression molding consolidation, helping customers further reduce takt times and lower manufacturing costs. Unlike many accelerated epoxy systems, 3960-FC exhibits a low exotherm risk for thick structures.

Product Highlights

• Proven mechanical properties equivalent to the 3960 NCAMP database
• Up to 45% reduction in cure time vs. 3960 autoclave cure
• Low exotherm risk compared to other accelerated epoxy systems
• Enables prototyping using lower-cost, lower-temperature tooling
• Improved vacuum bag only (VBO) and compression molding consolidation options

Target applications for 3960-FC include primary aircraft structures, mid- to large-size UAVs, launch vehicles and rockets, and rotorcraft structures.

Toray CMA offers a comprehensive portfolio of materials to support the full spectrum of aerospace and defense processing requirements, from traditional cure cycles to fast-cure systems, giving customers the flexibility to choose a solution that best fits their production environment and program needs.