1. Executive Summary
2. Carbon Fiber Snapshot
2.1. Overview
2.2. Carbon Fiber Value Chain
2.3. Carbon Fiber Market Characteristics
2.4. Carbon Fiber: Types
2.4.1. Continuous Fiber
2.4.2. Chopped Fiber
2.4.3. Milled Fiber
2.4.4. Metal Coated Fiber
2.5. Evolution of Carbon Fiber Applications
2.6. Key Success Factors for Rapid Carbon Fiber Adoption
2.7. Carbon Fiber Recycling
2.7.1. Recycled Carbon Fiber from Manufacturing and Cured Component
2.7.2. Recycled Carbon Fiber from End of Life Structures
2.7.3. Associations Related to Recycled Carbon Fiber from End of Life Structures
2.7.4. Recycled Carbon Fiber Markets
3. Emerging Carbon Fiber Applications
3.1. Overview
3.2. Methodology
3.3. Nuclear Centrifuge Rotor Tubes
3.3.1. Overview
3.3.2. Working of Nuclear Centrifuge Rotors
3.3.3. Evolution of Carbon Fiber Applications in Nuclear Centrifuges
3.3.4. Problems with Maraging Steel/Alloy Rotors
3.3.5. CFRP Centrifuge Rotor
3.3.6. Technology Roadmap
3.3.7. Growth Drivers for the use of CFRP in Nuclear Centrifuge Rotors
3.3.8. Challenges: Carbon Fiber in Nuclear Centrifuge Market
3.3.9. Opportunity Analysis in Nuclear Centrifuge Rotor Tubes
3.3.10. Hexcel, ATK and USEC Tripartite Supply Agreement
3.3.11. Key Success Factors
3.4. Consumer Electronics
3.4.1. Overview
3.4.2. Laptops
3.4.3. Apple Inc's Plan to Use Carbon Fiber in Laptops
3.4.4. Growth Drivers in Laptop Industry
3.4.5. Challenges in Laptop Industry
3.4.6. Market Potential Analysis in Laptop
3.4.7. Mobile Phones
3.4.8. Carbon Fiber Mobile Phone Case
3.4.9. Growth Drivers in Mobile Phone Industry
3.4.10. Challenges in Mobile Phone Industry
3.4.11. Potential Analysis in Mobile Phone Industry
3.5. Offshore Oil and Gas Applications
3.5.1. Industry Overview and Characteristics
3.5.2. Oil Drilling Technologies
3.5.3. Desired Material Properties for Offshore Oil and Gas Applications
3.5.4. CFRP Application Details
3.5.5. Drilling Riser with CFRP Choke and Kill Lines Benefits
3.5.6. TLP Tethers
3.5.7. Subsea Umbilicals
3.5.8. Major Contracts for Carbon Fiber Umbilicals
3.5.9. CFRP Advantages in Offshore Oil Industry
3.5.10. Technology Roadmap
3.5.11. Growth Drivers in Oil and Gas Industry
3.5.12. Challenges in Oil and Gas Industry
3.5.13. Opportunities in Oil and Gas Industry
3.5.14. Key Success Factors
3.6. Wind Energy
3.6.1. Overview
3.6.2. CFRP Application Details
3.6.3. Technology Roadmap
3.6.4. Growth Drivers in Wind Energy Markets
3.6.5. Challenges in Wind Energy Markets
3.6.6. Opportunity Analysis in Wind Energy Markets
3.6.7. Carbon Fiber Benefits in Wind Turbine Industry
3.6.8. Wind Turbine Blade Manufacturing Processes Comparison
3.6.9. Key Success Factors
3.7. High Pressure Tanks
3.7.1. Overview
3.7.2. Classification of Gas Storage Tanks
3.7.3. Characteristics of CFRP Gas Storage Tanks Market
3.7.4. Key Material Requirements
3.7.5. Technology Roadmap
3.7.6. Growth Drivers in Gas Storage Tanks
3.7.7. Challenges in Gas Storage Tanks
3.7.8. CFRP Overwrap in Type III CNG Cylinders
3.7.9. Opportunity Analysis in Gas Storage Tanks
3.7.10. Hydrogen Gas Storage
3.7.11. Key Success Factors
3.8. Automotive and Transportation
3.8.1. Overview
3.8.2. CFRP Application Details
3.8.3. Technology Roadmap
3.8.4. Growth Drivers in Automobile Industry
3.8.5. Challenges in Automobile Industry
3.8.6. Carbon Fiber Potential and Opportunity Analysis in Automobile Industry
3.8.7. Emerging Applications in Automobile Industry
3.8.8. CFRP Advantages in Automotive Industry
3.8.9. CFRP Recycling
3.8.10. Key Success Factors
3.9. Bridge Rehabilitation and Construction
3.9.1. Overview
3.9.2. Carbon Fiber Product Types Used in Construction Industry
3.9.3. Technology Roadmap
3.9.4. Growth Drivers in Bridge Rehabilitation
3.9.5. Challenges in Construction Industry
3.9.6. Opportunity Analysis in Construction Industry
3.9.7. Bridges
3.9.8. CFRP Bridge Advantages
3.9.9. Carbon Fiber Reinforced Concrete (CFRC)
3.9.10. Key Success Factors
3.1. Fuel Cell Applications
3.10.1. Overview
3.10.2. Fuel Cell Operation
3.10.3. Evolution and Research: Carbon Fiber in Fuel Cells
3.10.4. Commercialized Technologies: Carbon Fiber in Fuel Cells
3.10.5. Carbon Fiber Bipolar Plates
3.10.6. Gas Diffusion Layer (GDL)
3.10.7. Fuel Cell Cost Breakdown
3.10.8. Carbon Fiber Benefits in Fuel Cell
3.10.9. Technology Roadmap in Fuel Cell Markets
3.10.10. Growth Drivers in Fuel Cell Markets
3.10.11. Challenges in Fuel Cell Markets
3.10.12. Key Success factors
4. Medical and Biomedical Applications
4.1. Overview
4.1.1. Tabletops
4.1.2. Oncology Therapy
4.2. Surgical Tables
4.3. Human Organ Transportation Devices
4.4. Cranioplasty
4.5. Socket for an Artificial Limb
4.5.1. Overview
4.5.2. Socket Manufacturing Process
4.5.3. Advantages and Disadvantages
4.6. Endolign
5. Emerging Applications in Commercial Aerospace
5.1. Industry Overview and Characteristics
5.1.1. Cyclical in Nature
5.1.2. Backlog Driven Market
5.1.3. Secular Trend towards Composites
5.2. CFRP Application Details
5.3. Technology Roadmap in Commercial Aerospace Industry
5.4. Carbon Fiber Supply Chain for Commercial Aerospace
5.5. CFRP Advantages
5.5.1. Aircraft Cost of Ownership
5.5.2. Fuel Savings
5.5.3. Aircraft Maintenance Reduction
5.5.4. Impact of Corrosion in Aircraft
5.6. Growth Drivers in Commercial Aerospace Industry
5.7. Challenges in Commercial Aerospace Industry
5.8. Opportunities in Commercial Aerospace Industry
5.8.1. Existing Aircraft
5.9. Emerging Applications
5.9.1. Carbon Fiber in Volvo Engines
5.9.2. Airbus A350 XWB Fuselage
5.1. Key Success Factors
6. Recent and Future Applications
6.1. Overview
6.2. Carbon Fiber Debit/Credit Cards
6.3. Carbon Fiber Biometric Scanner Door
6.4. Carbon Fiber LCD TV
6.5. Carbon Fiber in Video Displays (MEMS)
6.6. GPS Telescopes
6.7. Baggage Scanning Tunnels
6.8. Carbon Fiber Guitars
6.8.1. Overview
6.8.2. Manufacturing Process
6.8.3. Advantages
6.9. Carbon Audio Video Racks
6.9.1. Overview
6.9.2. CFRP Benefits
6.1. Bikes
6.11. Carbon Fiber Tripods
6.12. Carbon Fiber Gun Grip
6.13. Carbon Fiber Shin Guard
6.14. Carbon Fiber Monowheel Exercise Bike
6.15. Carbon Fiber Tables
6.16. Carbon Fiber Trophies
6.17. Mercedes F-CELL
6.18. Ferrari Hybrid Car
6.19. Carbon Fiber Tires
6.2. Carbon Fiber Pedal for Rockband
6.21. Carbon Fiber Watches
6.22. Carbon Fiber Fins
6.23. Carbon Fiber Computer Case
6.24. Carbon Fiber Tramontana R, 720hp V12 Monster
6.25. New Carbon Fiber Snowboard Concept
6.26. Carbon Fiber Key Chain
6.27. Carbon Fiber Ring
6.28. Carbon Fiber Mouse and Mouse pad
6.29. Carbon Fiber Electric Razor
6.3. Carbon Fiber Xbox Controllers
6.31. Carbon Fiber Staircase
6.32. Carbon Fiber in Shoes
6.33. Carbon Fiber Helmets
6.34. Carbon Fiber Toilet Bowl
6.35. Carbon Fiber Tissue Box
6.36. Carbon Fiber Car Wheel
6.37. 2011 Kawasaki Ninja 1000 R-77 Slip-on systems
6.38. SMX-2 Air Carbon Gloves
6.39. Carbon fiber mirror holder
6.4. Ashby West Road Bridge
6.41. Carbon fiber athletic footwear
6.42. Carbon Fiber Prius X Parlee Bicycle
6.43. Carbon Fiber Canoe
List of Figures
List of Tables
Abbreviations and technical units
Disclaimer
Copyright
About Us
List of Figures
Chapter 1
Figure 1.1: Carbon fiber demand forecast for emerging applications in $ million shipments
Figure 1.2: Application production volume to per unit consumption
Figure 1.3: Life cycle placement of various applications in carbon fiber
Chapter 2
Figure 2.1: Carbon fiber value chain
Figure 2.2: Carbon fiber supply agreements
Figure 2.3: Different types of carbon fiber forms
Figure 2.4: Typical continuous carbon fiber
Figure 2.5: Typical chopped carbon fiber
Figure 2.6: Typical metal (nickel)-coated carbon fiber
Figure 2.7: Growth volume matrix for carbon fiber
Figure 2.8: Key success factors for carbon fiber adoption
Figure 2.9: Recycling process from manufacturing and cured component waste
Figure 2.10: Recycling process flow for end-of-life waste
Chapter 3
Figure 3.1: Nuclear fuel cycle
Figure 3.2: Working of nuclear centrifuge
Figure 3.3: Iraqi centrifuge components, destroyed by inspectors in the early 1990s
Figure 3.4: Comparison of rotor speed of various materials such as AL, MS, CFRP
Figure 3.5: Comparison of maximum length of rotor made using various materials such as AL, MS, CFRP
Figure 3.6: Comparison of uranium productivity by rotor made using various materials such as AL, MS, CFRP
Figure 3.7: Difference between various rotor materials
Figure 3.9: Technology roadmap for rotor tube materials
Figure 3.10: Technology roadmap for rotor tube speed
Figure 3.11: Technology roadmap for rotor tube uranium separation efficiency
Figure 3.12: Technology roadmap for rotor tube length
Figure 3.13: Penetration of centrifuge method in uranium separation
Figure 3.14: Leaders’ share in nuclear energy separative works unit market
Figure 3.15: Business units of Atomenergoprom with separate carbon fiber engineering division
Figure 3.16: Carbon fiber material flow diagram in Hexcel USEC agreement
Figure 3.17: Key success factors for carbon fiber in nuclear centrifuge market
Figure 3.18: Acer Ferrari 1000 carbon fiber laptop
Figure 3.19: Acer Ferrari 1100 carbon fiber laptop
Figure 3.20: Acer Ferrari 5000 carbon fiber laptop
Figure 3.21: Sony Viao TX carbon fiber body laptop
Figure 3.22: Apple’s patented carbon fiber scrim layer for MacBook
Figure 3.23: Apple MacBook weight distribution by component
Figure 3.24: Forecast (2011–2016) in mobile PCs shipment in million units
Figure 3.25: Carbon fiber potential in global laptop market
Figure 3.26: LG Black Label series carbon fiber mobile phone
Figure 3.27: LG Black Label series carbon fiber finished mobile phone
Figure 3.28: Nokia 8800 carbon arte phone
Figure 3.29: Carbon fiber case for iPhone
Figure 3.30: Global mobile phone shipments in million units
Figure 3.31: Regional distribution of mobile phones
Figure 3.32: Carbon fiber potential at different scenarios
Figure 3.33: ATP/NIST funded projects for CFRP risers and choke and kill lines
Figure 3.34: Most common floating production units
Figure 3.35: A typical tension leg platform
Figure 3.36: Different SPAR platform types
Figure 3.37: Different types of risers used in platforms
Figure 3.38: Application of production risers used in TLPs
Figure 3.39: Detailed view of riser
Figure 3.40: Production riser manufacturing process
Figure 3.41: Application of carbon fiber in choke and kill lines
Figure 3.42: Carbon fiber applications in tethers
Figure 3.43: Carbon fiber pultruded rods in tethers
Figure 3.44: Vello Nordic carbon fiber pultruded rods
Figure 3.45: Key technological developments of CFRP products in oil and gas industry
Figure 3.46: Shift in production riser material
Figure 3.47: Increase in average well depth in feet
Figure 3.48: Upcoming oilfields of more than 7,000 feet in depth
Figure 3.49: Growth in ultra-deepwater rigs
Figure 3.50: Oil production forecasts from deepwater rigs
Figure 3.51: Key success factors for carbon fiber in oil and gas industry
Figure 3.52: Integrated approach for offshore oil and gas product developments
Figure 3.53: Trend (2005-2010) in wind energy market in capacity (MW) installation
Figure 3.54: Different designs used to manufacture wind turbine blades
Figure 3.55: Cross-section view of wind turbine blades
Figure 3.56: Materials use in wind turbine
Figure 3.57: Carbon glass hybrid structure
Figure 3.58: Technology roadmap for types of wind turbine installations
Figure 3.59: Technology roadmap for materials used in wind turbine blades
Figure 3.60: Technology roadmap for increase in average turbine capacity with time
Figure 3.61: Global annual wind energy capacity (MW) installation forecast (2011–2016)
Figure 3.62: Penetration of 2.5 MW turbines in wind energy industry
Figure 3.63: Offshore floating wind turbine
Figure 3.64: Past, present, and future of wind turbine capacities
Figure 3.65: Carbon fiber applications in large size wind turbines
Figure 3.66: Multibrid M5000 production targets
Figure 3.67: Key success factors for carbon fiber in wind industry
Figure 3.68: Different kinds of tanks
Figure 3.69: Breakdown by cylinder type
Figure 3.70: Technology roadmap for cylinder wrapping
Figure 3.71: Technology for CFRP tanks
Figure 3.72: Trend (2005–2010) in CNG vehicles shipment in terms of units
Figure 3.73: Regional distribution of CNG vehicles in 2010 in terms of units
Figure 3.74: Regional trend (2005-2010) of CNG vehicles
Figure 3.75: Details of a hydrogen tank
Figure 3.76: Material weight breakdown of 70 MPa CFRP hydrogen tank
Figure 3.77: Material cost breakdown of 70 MPa CFRP hydrogen tank
Figure 3.78: Material weight breakdown of CFRP hydrogen tank
Figure 3.79: Material weight breakdown of 5,000 psi CFRP hydrogen tank
Figure 3.80: Material weight breakdown of 10,000 psi CFRP hydrogen tank
Figure 3.81: Key success factors for carbon fiber in gas storage tanks
Figure 3.82: Typical hood body weight comparison
Figure 3.83: CFRP shaft weight comparison
Figure 3.84: CFRP penetration in automotive industry
Figure 3.85: Material development in automotive industry
Figure 3.86: CFRP component production time in automotive industry
Figure 3.87: CFRP component weight comparison
Figure 3.88: Carbon fiber potential at different penetration levels
Figure 3.89: Structural weight of buses using CFRP and steel body
Figure 3.90: Carbon fiber interiors in BMW M6
Figure 3.91: Carbon fiber interiors in Mercedes SL65 AMG
Figure 3.92: Carbon fiber interiors in Chrysler 200C concept
Figure 3.93: Graph showing end-of-life vehicle targets
Figure 3.94: Toray’s CFRP recycling flow diagram
Figure 3.95: Key success factors for carbon fiber applications in automotive sector
Figure 3.96: Car component production time comparison – Toray’s method vs. conventional RTM
Figure 3.97: Flow diagram for CFCC preparation
Figure 3.98: Different kinds of CFCC
Figure 3.99: Smooth leadline rods
Figure 3.100: Spiral leadline rods
Figure 3.101: Intended concentric spiral leadline rods
Figure 3.102: Application flow diagram for carbon fiber tow sheet
Figure 3.103: Technology roadmap for CFRP applications
Figure 3.104: Status of US bridges
Figure 3.105: Carbon fiber potential scenarios in bridge rehabilitation
Figure 3.106: CFRP placement in bridge decks
Figure 3.107: Carbon fiber in bridge repair
Figure 3.108: XXsys Technologies corrosion retrofit process
Figure 3.109: Comparison between conventional concrete and carbon fiber reinforced concrete
Figure 3.110: Key success factors for carbon fiber in construction markets
Figure 3.111: Fuel cell stack
Figure 3.112: Carbon Fiber Cloth in GDL
Figure 3.113: SGL’s GDL and Bipolar Plates
Figure 3.114: CeTech’s N Series Carbon Paper
Figure 3.115: Bipolar plate for fuel cell
Figure 3.116: Gas diffusion layer
Figure 3.117: Neoplan’s fuel cell bus
Figure 3.118: Fuel cell cost distribution
Figure 3.119: Technology roadmap for fuel cell commercialization
Figure 3.120: Technology roadmap for use of carbon fiber in fuel cell
Figure 3.121: Trend in fuel cell megawatts shipped globally, 2008-2010
Figure 3.122: Fuel cell shipments by region
Figure 3.123: Expected launch year of fuel cell vehicle
Figure 3.124: Fuel cell shipment projections in transportation
Figure 3.125: Vehicle cost comparison with different power sources
Figure 3.126: Key success factors for carbon fiber in fuel cell markets
Chapter 4
Figure 4.1: Tabletops for various applications
Figure 4.2: X-ray transparency comparison – CFRP vs. traditional materials
Figure 4.3: CFRP applications in oncology
Figure 4.4: CFRP surgical table
Figure 4.5: A typical artificial limb: an above-the-knee prosthesis
Figure 4.6: CFRP artificial limbs
Figure 4.7: CFRP socket manufacturing process
Figure 4.8: Oscar Pistorius uses carbon fiber prosthetics in place of the lower legs
Figure 4.9: Endolite translaminar pins, intermedullary nails/screws
Chapter 5
Figure 5.1: Boeing and Airbus commercial aircraft delivery trend and forecast
Figure 5.2: Boeing and Airbus backlogs
Figure 5.3: Boeing and Airbus aircraft composites content by structural weight
Figure 5.4: Shift in Boeing aircraft composites content by structural weight
Figure 5.5: Shift in Airbus aircraft composites content by structural weight
Figure 5.6: CFRP applications in Airbus aircraft
Figure 5.7: Major CFRP applications in commercial aircraft
Figure 5.8: Technology roadmap for composites content in commercial aircraft
Figure 5.9: Technology roadmap for material development in commercial aircraft
Figure 5.10: Carbon fiber supply chain for commercial aerospace
Figure 5.11: Aircraft cost of ownership
Figure 5.12: Lifetime fuel savings by aircraft type
Figure 5.13: Corrosion-prone areas in an aircraft
Figure 5.14: Lower lobe frame shear-tie drainage
Figure 5.15: Lower lobe stringer drainage and sealing
Figure 5.16: CFRP benefits in aircraft
Figure 5.17: Fuel consumption rate by aircraft type
Figure 5.18: CFRP consumption trends in aircraft
Figure 5.19: Current opportunities in commercial aerospace industry
Figure 5.20: Boeing aircraft backlogs
Figure 5.21: Airbus aircraft backlogs
Figure 5.22: Airbus A350 XWB delivery forecasts
Figure 5.23: Airbus A350 XWB aircraft fuselage sections
Figure 5.24: Schematic diagram of Airbus A350 XWB fuselage
Figure 5.25: Airbus A350 XWB rear fuselage barrel
Figure 5.26: Key success factors for carbon fiber in aircraft structures
Chapter 6
Figure 6.1: Carbon fiber credit card
Figure 6.2: Carbon fiber scanning biometric door
Figure 6.3: Carbon fiber LCD television
Figure 6.4: GPS optical tube assembly
Figure 6.5: Carbon fiber optical tube
Figure 6.6: CFRP tunnel in baggage scanner
Figure 6.7: Front view of XOX audio tools guitar
Figure 6.8: Side view of XOX audio tools guitar
Figure 6.9: Gus G1 silver carbon fiber guitar
Figure 6.10: Carbon fiber audio video racks
Figure 6.11: B-120 Wraith bike
Figure 6.12: Honda CB 750 Motorcycle
Figure 6.13: Carbon fiber tripod
Figure 6.14: Carbon fiber in gun grip
Figure 6.15: Carbon fiber shin guard
Figure 6.16: Carbon fiber in exercise bike
Figure 6.17: Carbon fiber in tables
Figure 6.18: Carbon fiber trophies
Figure 6.19: Mercedes F-cell
Figure 6.20: Carbon fiber in Goodyear tire
Figure 6.21: Carbon fiber Rock Band pedal
Figure 6.22: Carbon fiber wrist watch
Figure 6.23: Carbon fiber fins
Figure 6.24: Carbon fiber computer case
Figure 6.25: V12 monster
Figure 6.26: Carbon fiber snowboard
Figure 6.27: Carbon fiber key chain
Figure 6.28: Carbon fiber ring
Figure 6.29: Carbon fiber in mouse pad
Figure 6.30: Carbon fiber electric razor
Figure 6.31: Carbon fiber in Xbox game controllers
Figure 6.32: Carbon fiber staircase
Figure 6.33: Carbon fiber in Puma shoes
Figure 6.34: Carbon fiber helmet
Figure 6.35: Carbon fiber toilet bowl
Figure 6.36: Carbon fiber tissue box
Figure 6.37: Carbon fiber car wheel
Figure 6.38: 2011 Kawasaki Ninja 1000 R-77 Slip-on systems made using carbon fiber
Figure 6.39: Alpinestars SMX-2 air carbon glove
Figure 6.40: Lumma Design carbon fiber side mirror for BMW 7 series
Figure 6.41: Construction of Ashby West Road Bridge
Figure 6.42: Carbon fiber athletic footwear
Figure 6.43: Carbon fiber Prius X Parlee Bicycle
Figure 6.44: Carbon fiber canoe
List of Tables
Chapter 1
Table 1.1: Summary of emerging applications
Chapter 2
Table 2.1: Carbon fiber applications timeline
Chapter
Table 3.1: CFRP production riser specifications
Table 3.2: Drilling riser with choke and kill lines specifications and performance comparison