HZ info,Tokyo, Japan, January 27, 2026 – Toray Industries, Inc., announced today that it has successfully completed its tests on a technology that bonds carbon fiber reinforced plastic (CFRP) aircraft mock-up structures almost three times faster than conventional approaches.

Thermoset CFRP (see note 1) 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 (note 2), well？suited for high？rate production and offers high design flexibility, have also expanded. By combining thermoset and thermoplastic CFRP, there are anticipations for new airframes with enhanced performance and productivity. However, such conventional techniques as adhesive bonding and bolted fastening add complexity and slow production, creating a strong need for bonding technologies that improve both productivity and reliability.

Toray drew on years of expertise in CFRP intermediate material (prepreg) manufacturing and in CFRP molding and processing, to develop a thermal welding technology that bonds thermoset and thermoplastic CFRP. This delivers higher bonding strength than conventional adhesive bonding (see note 3 and Figure 1). It also makes bonding for simulated aircraft structures (Figure 2) three times faster than that needed for 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’ (note 4), supported by the New Energy and Industrial Technology Development Organization (NEDO). Toray will exhibit its breakthrough at ‘nano tech 2026 (the 25th International Nanotechnology Exhibition & Conference)’ held at Tokyo Big Sight from January 28 through 30, 2026.

Toray has stated in its Sustainability Vision that it is committed to providing innovative technologies and advanced materials to help address global issues. The company will continue to innovate materials and technologies for a carbon-neutral economy, in line with its corporate philosophy of “contributing to society through the creation of new value with innovative ideas, technologies and products.”

Figure 1: Relative bonding strengths of thermosetting and thermoplastic CFRP

Figure 2. Aircraft mock-up structure made with Toray’s technology
Note: Thermoset CFRP used to manufacture skin, stringers, and frames, with thermoplastic CFRP or injection material used to make clips. Parts assembled by thermally welding them (structure size is 900mm x 600mm).