Aerospace and defence: Toray launches fast-curing variant of 3960 prepreg system

Toray Composite Materials America has announced the launch of the 3960-FC, a fast-curing variant of the 3960 prepreg system, renowned for its high performance and strength, designed for critical aerospace and defence applications.

Toray Composite Materials America (TCMA), which manufactures and supplies the proprietary Torayca carbon fibre as well as state-of-the-art thermoset prepreg materials, has launched the 3960-FC, a prepreg system developed to help original equipment manufacturers (OEMs) and their supply chains meet the growing demands for production rates in next-generation single-aisle commercial aircraft programmes, advanced air mobility platforms and new mission-critical defence systems produced in series.

“Increased pressure is being placed on material suppliers to provide a structural material solution with production rates now higher than what manufacturers have historically supported,” said Jeff Cross, principal director of defence programmes. “3960-FC accelerates manufacturing cycles while maintaining the mechanical and structural performance customers expect from our premier product, the 3960 prepreg system, by demonstrating equivalence with the material data in the 3960 NCAMP database.”

The 3960-FC offers proven mechanical properties equivalent to those listed in the NCAMP database for the 3960: high toughness, performance at high temperatures and in humid environments, tensile strength, stiffness and damage tolerance. Furthermore, it is fully compatible with a wide range of automated manufacturing technologies, including automated fibre placement (AFP) and automated tape laying (ATL), as well as traditional processing methods. Furthermore, 3960-FC allows the use of lower-temperature moulds, thereby reducing tooling costs while expanding the processing margins for vacuum bag-only (VBO) applications. 3960-FC also enables compression moulding, helping customers to further reduce cycle times and lower manufacturing costs. Unlike many accelerated-cure epoxy systems, the 3960-FC presents a low risk of exothermic reactions in thick sections. Compared with autoclave curing of the 3960, the 3960-FC reduces curing time by up to 45 per cent.

The 3960-FC is primarily intended for primary aircraft structures, medium to large drones, launch vehicles and rockets, as well as rotary-wing aircraft structures.

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