4000 Prepreg System
Data Sheet
PRODUCT NOTES

4000 prepreg system features a toughened bismaleimide (BMI) resin system specifically formulated for aircraft primarystructures demanding enhanced strength and toughness in high service temperature environments up to 450°F (232°C).
When compared to other BMI prepregs on the market, Toray’s 4000 prepreg system outperforms the competition while
maintaining the familiar handling and flow characteristics of traditional epoxy prepregs.

PRODUCT SPECIFICATIONS

The 4000 prepreg system has been tested using the following product forms, however customized configurations arepossible with numerous types of TORAYCA™ unidirectional carbon fibers, woven carbon, or glass fabrics. Fiber Areal Weights(FAW) can range from 70 g/m2 to 300 g/m2 while Resin Content (RC %) by weight percent typically ranges from 24% to 40%.
Requests for configurations beyond these ranges are possible.
Unidirectional products can be slit to widths between 1/8” and 60”, and fabric products to widths between 6” and 60”.
Common product formats include ¼”, ½”, 1”, and 1.5” AFP spools (UD only); 6”, 500mm, 9”, and 12” ATL rolls; and 24” tofull-width rolls for hand layup. Product widths narrower than 3” require additional lead time.
PREPREG DESCRIPTIONRESIN CONTENT (WT%)

FAW (G/M2)

AVAILABLEWIDTHS

CURED PLY THICKNESSCarbon UD Tape
(T800G-24K-F1E/4000)

35

145

1/8 to 60in
(3 – 1524mm)

0.0058in(0.147mm)

Carbon UD Tape
(T1100G-12K-F1E/4000)

35

145

1/8 to 60in
(3 – 1524mm)

0.0057in(0.145mm)

HANDLING AND STORAGE LIFE
STORAGE CONDITION

TIME

NOTES

< 10°F (-12°C)

12 Months

Keep in sealed container until thawed

10 – 85°F (-12 – 30°C)

14 Days

Tack may be increased by increasing temperature; please contact us formore information

NEAT RESIN DATATEST TYPEMETHODVALUENOTESDensity

ASTM D595

1.272 g/cm3-Gel Time

ASTM D3532

13 minutes

Tested at 350°F (177°C)

Cured Tg

ASTM D7028

Dry: 484°F (251°C)
Wet: 453°F (234°C)

Wet conditioning: H2O soak at
208°F (98°C) for 24 hours

www.toraycma.com | (253) 846-1777 | salescma@toraycma.com

BAGGING SCHEME*FEP is optional if the tool/mold is coated with a release agent

Note: The double bag scheme illustrated above is the recommended technique for 4000 prepreg system, however
traditional bagging methods used for epoxy prepreg systems may be compatible. Please contact Toray CMA for information.
••
•
•
•
•

The FEP between the tool surface and the part (if used) needs to be stretched tight to prevent surface defects.
The fiberglass strand wrapped around the prepreg should be pressed tightly against the side of the prepreg.
The distance between the edge of the prepreg and the sealant tape should be at least 1.75 mm.
The FEP between the prepreg and the caul plate (if used) should have no wrinkles on the portion contacting theprepreg. It should also cover the resin trap. A small hole should be made in the FEP above the coiled fiberglass in theresin trap.
A 10 oz surface breather is placed between the caul plate and the FEP to prevent the caul plate from puncturing theFEP.
If post-cure will immediately follow initial cure, please ensure bagging materials and autoclave hosing are rated forthe post-cure cycle’s max temperature of 440 ± 10°F (227 ± 5°C).

STANDARD CURE CYCLE

Note: This resin system requires a high-temperature post-cure to obtain optimal mechanical performance. Alternate postcure temperatures and hold times may be used to tune the system’s Tg and toughness properties; please contact Toray CMA
for more information.
Initial Cure Steps
1. De-bulk every four plies, or as needed, when laying up material.
2. Apply full vacuum* to the part. The vacuum should be checked for leaks before beginning the cure cycle. The leak rateshall be less than 1 psi over 5 minutes.
3. Apply 85 ± 0 psi autoclave pressure to the laminate.
4. Ramp to 290 ± 10°F at 3°F/min (143 ± 5°C at 1.7°C/min) and hold for 120 minutes.
5. Ramp to 375 ± 10°F at 3°F/min (191 ± 5°C at 1.7°C/min) and hold for 120 minutes.
6. Cool temperature down to 77°F at max rate of 3°F/min (77°C at 1.7°C/min) and vent/release autoclave and vacuum
pressure.
Post-Cure Steps
1. The post-cure cycle may be initiated immediately after the initial cure’s cooldown step provided that the bagging
materials and autoclave hosing are rated to withstand 440°F (227°C), or free-standing in an air-circulating oven.
2. Ramp to 440 ± 10°F at 3°F/min (227 ± 5°C at 1.7°C/min) and hold for 240 minutes.
3. Cool temperature down to 77°F at max rate of 3°F/min (77°C at 1.7°C/min).
*Required vacuum level varies depending on elevation. 13.78 psi is the recommended minimum at sea level under average
conditions.

RESIN VISCOSITY CURVEMECHANICAL PROPERTIES – STANDARD CURE & POST-CURE
TESTMETHODTEST TYPETESTCONDITION

T800G UDT1100G UD

CTA
RTA
ETW 180°F
ETA

395
413
419
411

(2723)(2845)(2885)(2832)

456
460
502
479

(3145)(3174)(3463)(3300)

Modulus:Msi (GPa)

CTA
RTA
ETW 180°F
ETA

23.7
22.8
22.5
22.8

(163)
(157)
(155)
(157)

26.4
26.1
26.1
25.7

(182)
(180)
(180)
(177)

0° Combined Loadin
Compression (CLC)*(T1100G: [0°]20; T800G: [0°]16)

Strength:
Ksi (MPa)

ASTM D6641

CTA
RTA
ETW 180°F
ETA

216
226
181
204

(1486)(1558)(1248)(1407)

223
203
171
186

(1539)(1397)(1177)(1283)

Compression After Impact(RTA)

Strength:
Ksi (MPa)

ASTM D7137

1500 in-lb/in1000 in-lb/in

42.1
47.9

(290)
(330)

44.5
51.7

(307)
(356)

CTA
RTA
ETW 180°F
ETA

22.2
23.3
17.4
18.6

(153)
(161)
(120)
(128)

24.6
23.7
16.9
16.0

(170)
(163)
(117)
(110)

CTA
RTA
ETW 180°F
ETA

0.85
0.73
0.54
0.60

(5.9)
(5.0)
(3.7)
(4.1)

0.90
0.76
0.54
0.61

(6.2)
(5.2)
(3.7)
(4.2)

Strength:
Ksi (MPa)
0° Tension*

ASTM D3039

Strength:
Ksi (MPa)±45° In-Plane Shear

ASTM D3518
Modulus:Msi (GPa)*Normalized to 60% Vf
RTA: Testing performed at 75°F (24°C), as-received moisture content
CTA: Testing performed at -65°F (-54°C), as-received moisture content
ETW: Testing performed at the stated temperature, conditioned by H2O soak at 160°F (71°C) for 2 weeks
ETA: Testing performed at 250°F (121°C), as-received moisture content

TEST TYPE

Open Hole Tension*

Open Hole Compression*

Strength:
Ksi (MPa)

Strength:
Ksi (MPa)

Strength:
Ksi (MPa)
QI Unnotched Tension*Modulus:
Msi (GPa)Strength:
Ksi (MPa)
QI Unnotched Compression*
Modulus:Msi (GPa)

0° Short Beam Shear*

Double Shear Bearing
Tension, Procedure A*

TESTMETHODTESTCONDITION

ASTM D5766

CTA
RTA
ETA

66.4
70.7
77.8

(458)
(488)
(536)

77.6
84.8
90.6

(535)
(584)
(624)

ASTM D6484

RT
ETW 180°F
ETW 250°F
ETW 300°F

45.0
40.4
36.5
37.1

(310)
(278)
(252)
(256)

48.9
44.7
42.5
39.5

(337)
(308)
(293)
(273)

CTA
RTA
ETA
ETW 180°F

143
148
148
150

(987)
(1020)(1019)(1034)

154
160
167
165

(1060)(1106)(1150)(1137)CTA
RTA
ETA
ETW 180°F

8.8
8.5
8.1
8.5(61)
(59)
(56)
(58)

9.6
9.4
8.7
9.3(66)
(65)
(60)
(64)

RTA
ETA
ETW 180°F

103
78
81(711)
(539)
(561)

111
85
87(763)
(584)
(597)

RTA
ETA
ETW180°F

7.8
9.9
7.3(54)
(68)
(50)

8.2
9.2
8.6

(57)
(63)
(59)

20.1
13.1
11.0
9.6
8.0
-

(139)
(90)
(76)
(66)
(55)
-

19.5
12.7
10.6
8.2
7.4
6.6

(135)
(88)
(73)
(56)
(51)
(46)122124(845)(855)127
127(878)(876)

ASTM D3039
ASTM D5766

ASTM D8066
ASTM D6484

Strength:
Ksi (MPa)

ASTM D2344

RTA
ETW 180°F
ETW 250°F
ETW 300°F
ETW 350°F
ETW 375°F

Strength:
Ksi (Mpa)

ASTM D5961

RTA
ETW 180°F

T800G UD

T1100G UD*Normalized to 60% Vf
RTA: Testing performed at 75°F (24°C), as-received moisture content
CTA: Testing performed at -65°F (-54°C), as-received moisture content
ETW: Testing performed at the stated temperature, conditioned by H2O soak at 160°F (71°C) for 2 weeks
ETA: Testing performed at 250°F (121°C), as-received moisture content

The data listed herein are lot averages, for reference purposes only, and are offered AS-IS without warranty. The results are not intended for specification purposes. WARNING: This
document may contain technical data whose export is restricted by the Export Administration Act of 1979, as amended, Title 50, U.S.C., App.2401 et seq. Violations of these export laws aresubject to severe criminal penalties.
4000 Prepreg System_Rev.5.5.2022

 www.toraycma.com
 salescmacontact@toraycma.com
 253-846-1777 • 800-208-6729

www.toraycma.com | (253) 846-1777 | salescma@toraycma.com