OAK RIDGE NATIONAL LABORATORY

“We transfer carbon fiber technology to industry partners to 

increase US competitiveness in manufacturing. This, in turn, 

supplies a critical need for our country, creates opportunities, and 

stimulates the economy.”

Merlin Theodore, Advanced Fibers Manufacturing Group Leader

Carbon Fiber Innovation

ADVANCING

carbon fiber

REDUCING

material costs

OPTIMIZING

feedstock properties

EVALUATING

raw materials

CREATING

job growth 

Oak Ridge National Laboratory (ORNL) is advancing carbon fiber research by evaluating and identifying high-potential, low-cost 

raw materials including textile, lignin, polymer, and hydrocarbon-based precursors. Research is enabling low-cost carbon fiber 

for use in clean energy and accelerating deployment in applications such as wind energy, hydrogen storage, building envelopes, 

and lightweight vehicles. Technology development and process optimization lead to the licensing of inventions including plasma 

processing for rapid carbon fiber production.

The Carbon Fiber Technology Facility (CFTF), a US Department of Energy (DOE) User Facility at 

ORNL, provides resources for developing innovative processes for further understanding the 

kinetics of carbon fiber manufacturing, energy consumption, and environmental impact. In 

addition, the CFTF provides carbon fiber sample quantities to industrial partners for testing for 

continuous improvement and market evaluation.

Research and Development

Thermal (conventional) conversion—Producing up to 25 tons/year of polyacrylonitrilebased fiber with ability to convert both melt-spun and solution-spun precursors

Melt-spun precursor fiber—Developing and optimizing a variety of precursors including 

polyethylene fiber, spun lignin, and pitch-based in either tow or web form

Advanced technology conversion—Delivering advances in conversion technology 

based on microwave and plasma-processing technologies 

Materials characterization—Utilizing advanced equipment including pultruder and 

steam stretcher to analyze custom composite materials and reduce oxidation time

Process optimization—Leveraging steam stretching textile winder/packaging and 

chopping capabilities to improve the production and delivery of carbon fiber

Artificial intelligence—Creating a data analytic framework that utilizes machine 

learning/statistical analysis, computer vision/quality control, sensing, management, tracking, 

and visualization

Advanced composites—Enabling broader use of advanced composites by lowering 

carbon fiber costs through textile precursor innovations and the investigation of composite 

production techniques including compounding, prepreg, braiding, and pultrusion
Oak Ridge National Laboratory is managed by UT-Battelle LLC for the US Department of Energy January 2022

Recent Impacts

Filter media production—Collaborated with industry to produce enough specialty filter 

media to supply more than 1 million face masks and respirators each day to US healthcare 

facilities for the ongoing COVID-19 pandemic, including the development of a novel, in-line 

charging device to mass-produce precursor material for N95 masks

Economic development—Utilized N95 filter media production process in collaboration 

with a medical device maker that resulted in the capability to mass-produce respirator masks, 

adding 500 jobs in the United States

Automotive lightweighting—Developed low-cost textile carbon fiber that was used to 

produce the first large injection-molded automotive prototype, a lightweight fender

Computational modeling—Created a 3D multiphysics computational model for the 

carbonization process that was faster and more energy efficient

Textile-based precursor—Developed carbon fiber using textile-based precursor; also 

pelletized and compounded the fiber

Equipment advancement—Developed chopping equipment for textile carbon 

fiber at various lengths and sizes; developed chopping equipment for commercial 

packaging methods

Additive applications—Utilized textile carbon fiber for large-scale additive 

manufacturing of a car hood mold

CONTACT:

Merlin Theodore

Group Leader

Advanced Fibers 

Manufacturing Group

theodorem@ornl.gov

865-576-6569

One Bethel Valley Road, 

Oak Ridge, TN 37830

ornl.gov/manufacturing

Unique Facilities

DOE Carbon Fiber Technology Facility (CFTF) assists industry with overcoming 

the barriers associated with cost and technology scaling of low-cost fibers and 

associated composites, including product and market development. The CFTF 

identifies high-potential, low-cost raw materials such as textile, lignin, 

polymer, and hydrocarbon-based precursors and houses a highly flexible 

manufacturing line rated for 25 tons per year and a precursor meltspinning line rated at 65 tons per year.

DOE Manufacturing Demonstration Facility (MDF)

creates and accelerates next-generation advanced 

manufacturing technologies, where materials, processes, 

and systems are holistically integrated to strengthen the 

US manufacturing base. Researchers at the MDF develop 

new tools and methods that are more cost-effective, 

efficient, and reliable for the nation’s security, economy, 

and energy portfolio. Through a robust technology 

transfer program, the MDF provides industry partners 

affordable and convenient access to facilities, tools, 

and expertise to facilitate rapid deployment of new 

technologies and clean energy solutions.

91

Industry

partners

14

University

partners

12

National

laboratory

partners

4

Licensed

technologies