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Feb.2026 12
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Carbon Fiber Reinforced Composites: Thermoset vs. Thermoplastic
Introduction
Carbon Fiber Reinforced Composites consist of resin and carbon fiber, and there are two types of resins, thermoset and thermoplastic.
Details
Thermoset materials usually come in the form of prepregs (carbon fibers pre-impregnated with epoxy resin) which requires manual layup of the carbon cloths as the layup schedule requires. Thermoset carbon fiber is soft (forming state) at room temperature or lower, and solidifies at heating. And the process is not reversible by re-melting the products. Thermoplastic carbon fiber composites are recyclable as it becomes soft at high temperature and cooling makes it become solid. The thermoplastic carbon products can be remelted to get carbon fibers for re-use.
Thermoset carbon fiber (Epoxy Resin)
Thermoset carbon fiber composites are typically made using prepregs, where carbon fibers are pre-impregnated with epoxy resin. This type of material remains soft at room temperature or below, solidifying once heated. The curing process is irreversible, meaning the material cannot be remelted.
Pros of Thermoset carbon fiber
Superior Stiffness: Offers excellent resistance to deformation, making it ideal for components requiring high structural integrity.
High Temperature Resistance: Maintains its properties at elevated temperatures.
Lower Manufacturing Costs: More cost-effective for large production runs.
Lightweight: Generally results in a lighter final product, which enhances overall performance.
Cons of thermoset carbon fiber
Labor-Intensive: Requires more manual intervention, making the production process time-consuming.
Brittle: Prone to cracking, especially under impact.
Non-Recyclable: Cannot be reprocessed or reused, limiting its sustainability.
Storage Requirements: Raw materials need to be refrigerated to maintain their properties.
Thermoplastic carbon fiber composites utilize a resin that softens at high temperatures and solidifies upon cooling. This reversible process allows for the recycling of thermoplastic composites, which is a significant advantage for sustainable manufacturing.
Thermoplastic carbon fiber composites utilize a resin that softens at high temperatures and solidifies upon cooling. This reversible process allows for the recycling of thermoplastic composites, which is a significant advantage for sustainable manufacturing.
Pros of thermoplastic carbon fiber
High Tensile Strength: Offers exceptional mechanical properties, making it ideal for parts under stress.
Fast Production Cycle: Allows for rapid manufacturing, reducing lead times and improving production efficiency.
Recyclability: Can be remelted and reformed, making it a more sustainable option compared to thermosets.
Vibration Damping: Known for its ability to absorb vibrations, enhancing ride comfort in bicycle components.
Cons of thermoplastic carbon fiber
Higher Cost: The manufacturing process and raw materials are generally more expensive.
Limited High-Temperature Durability: Not as resistant to high temperatures as thermoset composites. (the PAEK resin is stable under 150℃)
At NTP, we’ve always been dedicated to producing high-quality carbon fiber products. For years, we’ve specialized in thermoset carbon fiber, renowned for its superior stiffness and performance. Recently, however, we’ve entered into a strategic partnership with a local supplier of thermoplastic carbon fiber solutions. This collaboration allows us to offer an expanded range of products, including smaller components like carbon thru-axles, spokes, and bottle cages.
The introduction of thermoplastic carbon fiber into our manufacturing process brings multiple advantages: faster production cycles, greater recyclability, and the ability to produce more flexible components. While thermoset materials continue to dominate in high-performance applications requiring maximum rigidity, thermoplastic composites offer a sustainable, cost-effective alternative for certain smaller components.
At NTP, we’re excited to combine the best of both worlds and deliver even more flexibility and performance to our customers.
