Advanced Structural Carbon Products: Fibers, Foams & Composites

REPORT HIGHLIGHTS

THIS REPORT CONTAINS:

• Coverage of the technological, economic, and business conditions in the structural carbons industry
• Analyses of market trends, with data from 2010, estimates for 2011, and projections of compound annual growth rates (CAGRs) through 2016
• Explanations of the types of materials in the industry, including carbon fibers, carbon foams, monolithic structural graphite, and carbon-reinforced carbon composites
• A focus on the U.S. market, but analysis and forecasts also are provided for global markets
• Discussion of international aspects of the industry with respect to all the geographic regions and types of material
• Comprehensive company profiles of major manufacturers.

REPORT SCOPE

INTRODUCTION

STUDY GOALS AND OBJECTIVES

The overall goal of this study is to provide a comprehensive understanding of advances in structural carbon materials manufacturing, their commercial applications, and worldwide markets.  For the purposes of this report, these materials are defined to include all types of carbon fibers, carbon foams, monolithic structural graphite, carbon-reinforced carbon composites, and certain graphene materials.Specific objectives of the study include describing the major types of structural carbon materials, including key physical and chemical properties, raw materials, and manufacturing processes.  Commercial applications in which these materials are used will be discussed.Present consumption and future demand for these materials will be evaluated for the United States and other major geographical markets.  Trends in technology will be analyzed and forecasted.  The impact of governmental regulations will be assessed.  The dynamics of the structural carbons industry will be outlined along with profiles of key manufacturers.

REASONS FOR DOING THE STUDY

This study is an update of an earlier BCC report that was published in 2009.  The structural carbon materials industry and markets have continued to develop in the two and a half years since the previous edition was published.The structural carbon materials industry serves mature markets such as defense and aerospace, with a wide variety of products satisfying the requirements of well-established applications.  However, continuous technical innovations and efforts to make structural carbon technologies available for new applications (at affordable prices) are leading to the development of new markets.Corporations in the structural carbons industry need understand the significance of these trends to manage their enterprise and resources effectively.  Users of structural carbons must also understand the effect of these changes in order to select the most cost-effective option among newly available products and technologies prior to committing significant capital resources.

INTENDED AUDIENCE
Over the next half-decade significant change will take place in global structural carbon products and applications.  Technological advances in improving structure-property relationships of advanced carbon materials and breakthroughs in the manufacturing processes—resulting in lower costs—will lead to novel applications.  This study analyzes the driving forces that will shape the structural carbons industry over next few years.

Consequently, the information presented in this study should be useful to:

• Members of the financial community who must understand, assess, and rate the effect of forthcoming changes in the structural carbons industry based upon the financial performance of the companies active in this market segment
• Chief executive officers who must effectively manage the assets of their company so as to benefit from forthcoming changes in the structural carbons industry
• Directors of planning who must incorporate anticipated changes in the structural carbons industry into corporate planning documents
• Directors of manufacturing who must implement new structural carbons technology and products into their operations
• Directors of engineering, research, and development who must incorporate the latest in structural carbons technology and products into their designs and projects
• Decision makers at major structural carbons consumers, such as the Department of Defense contractors involved in aerospace and aircraft manufacturing
• Executives at companies engaged in developing competitive materials and technologies such as other reinforcement fibers like Kevlar or composites manufactured with other matrix materials such as ceramics or metal.

SCOPE OF REPORT

This report covers technological, economic, and business conditions in the structural carbons industry.  Although this report is primarily a study of the U.S. market, analysis and forecasts are also provided for global markets.  Included in this report are descriptions of market forces relevant to the structural carbons industry and their areas of application.The U.S. market is presented by type of structural carbons along with growth forecasts through 2016.  The driving forces in the industry and the structure of the industry are also examined.International aspects of the structural carbons industry are discussed with respect to all the geographic regions and type of structural carbon material.  Lastly, brief profiles of the major manufacturers are presented.

METHODOLOGY AND INFORMATION SOURCES
The report’s findings and conclusions are based on information gathered from a wide range of primary and secondary sources, including vendors, users, and engineering and consulting firms.  Interview data were combined with information gathered through an extensive review of secondary sources such as trade publications, trade associations, company literature, and online databases to produce the projections contained in this report.
The base year for analysis and projection is 2010.  With 2010 as a baseline, market projections were developed for 2011 to 2016.  These projections are based on a combination of a consensus among industry sources, combined with BCC’s understanding of the key market drivers and their impact from a historical and analytical perspective.

Table of Contents :

Chapter- 1: INTRODUCTION - Complimentary 5 $0
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE OF REPORT
METHODOLOGY AND INFORMATION SOURCES

Chapter- 2: SUMMARY 2 $150
Table 0 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, THROUGH 2016
Figure 0 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, 2010–2016

Chapter- 3: INDUSTRY AND MARKETS OVERVIEW 7 $231
UNITED STATES MARKET
GLOBAL MARKETS
RESEARCH AND TECHNOLOGY TRENDS
INDUSTRY STRUCTURE

Chapter- 4: TECHNICAL OVERVIEW 83 $2745
INTRODUCTION TO ADVANCED STRUCTURAL CARBON PRODUCTS
IMPORTANCE OF MECHANICAL PROPERTIES
CARBON FIBERS
CARBON FOAMS
STRUCTURAL GRAPHITE
CARBON-CARBON STRUCTURAL COMPOSITES
GRAPHENE

Chapter- 5: COMMERCIAL APPLICATIONS 75 $2480
CARBON FIBER APPLICATIONS
CARBON FOAM APPLICATIONS
STRUCTURAL GRAPHITE APPLICATONS
CARBON-CARBON COMPOSITES APPLICATIONS
STRUCTURAL GRAPHENE APPLICATIONS
MARKETS FOR ADVANCED STRUCTURAL CARBONS
Table 31 : U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF MATERIAL, THROUGH 2016
Figure 13 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016
Table L13 :
Table 32 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF MATERIAL, THROUGH 2016
Figure 14 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016
Table L14 :

Chapter- 6: INDUSTRY STRUCTURE AND MARKET DRIVERS 16 $529
MARKETS FOR STRUCTURAL CARBON MATERIALS
MARKET DRIVERS
COMPETITIVE STRATEGIES IN THE STRUCTURAL CARBONS INDUSTRY

Chapter- 7: INTELLECTUAL PROPERTY AND TECHNOLOGY TRENDS ANALYSIS 3 $99
INTELLECTUAL PROPERTY ANALYSIS
TECHNOLOGY DEVELOPMENT TRENDS

Chapter- 8: INTERNATIONAL ASPECTS OF STRUCTURAL CARBONS BUSINESS 3 $99
Table 34 : GLOBAL MARKET FOR STRUCTURAL CARBON BY TYPE OF MATERIAL, 2010
Figure 19 : COMPARISON OF ADVANCED STRUCTURAL CARBONS CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2010
Table L19 :
Table 35 : GLOBAL STRUCTURAL CARBONS MARKET GROWTH BY REGION, THROUGH 2016

Chapter- 9: PROFILE OF MANUFACTURERS 26 $860
U.S. MANUFACTURERS
INTERNATIONAL MANUFACTURERS

List of Tables
Summary Table : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, THROUGH 2016
Table 1 : DEPENDENCE OF CARBON FIBER PROPERTIES ON RAW MATERIALS
Table 2 : STRUCTURAL PROPERTY RELATIONSHIPS FOR CARBON FIBERS DERIVED FROM VARIOUS PRECURSORS
Table 3 : TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED POLYMER COMPOSITES
Table 4 : TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED METAL COMPOSITES
Table 5 : PROPERTIES OF PITCH RAW MATERIALS USED FOR CARBON FOAM MANUFACTURING
Table 6 : PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS
Table 7 : PHYSICAL PROPERTIES OF GRAPHITE MATERIALS
Table 8 : ADVANTAGES AND DISADVANTAGES OF CARBON-CARBON COMPOSITES
Table 9 : COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND CARBON-CARBON COMPOSITES
Table 10 : COMPARISON OF CARBON-CARBON COMPOSITES PROPERTIES MANUFACTURED BY VARIOUS PROCESSING ROUTES
Table 11 : PROPERTIES AND APPLICATIONS OF CARBON FIBERS
Table 12 : U.S. SPACE VEHICLE MARKET, THROUGH 2016
Table 13 : SALES OF U.S. MILITARY AIRCRAFT, THROUGH 2016
Table 14 : U.S. MISSILE SHIPMENTS, THROUGH 2016
Table 15 : DELIVERIES OF LARGE U.S.-MADE COMMERCIAL AIRCRAFT BY TYPE, THROUGH 2016
Table 16 : CONSUMPTION OF CARBON-FIBER-REINFORCED COMPOSITES IN U.S.-MADE BOEING COMMERCIAL AIRLINERS
Table 17 : TRENDS IN U.S. WIND POWER CAPACITY, THROUGH 2016
Table 18 : U.S. MARKET FOR WIND TURBINE ROTOR BLADES, THROUGH 2016
Table 19 : U.S. MARKET FOR CARBON FIBER COMPOSITE GOLF CLUBS, THROUGH 2016
Table 20 : U.S. SHIPMENTS OF CARBON FIBER FISHING RODS, THROUGH-2016
Table 21 : U.S. CONSUMPTION OF CARBON FIBERS, THROUGH 2016
Table 22 : U.S. MARKET FOR CARBON FIBERS, THROUGH 2016
Table 23 : U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2016
Table 24 : U.S. CARBON FOAM MARKET GROWTH BY INDUSTRY, THROUGH 2016
Table 25 : TYPICAL APPLICATIONS FOR GRAPHITE BEARINGS
Table 26 : U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY, THROUGH 2016
Table 27 : U.S. MARKET FOR STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, THROUGH 2016
Table 28 : U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2016
Table 29 : U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2016
Table 30 : U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY, THROUGH 2016
Table 31 : U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF MATERIAL, THROUGH 2016
Table 32 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF MATERIAL, THROUGH 2016
Table 33 : PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL CARBON MATERIALS TECHNOLOGY, 1996–2010
Table 34 : GLOBAL MARKET FOR STRUCTURAL CARBON BY TYPE OF MATERIAL, 2010
Table 35 : GLOBAL STRUCTURAL CARBONS MARKET GROWTH BY REGION, THROUGH 2016

List of Figures
Summary Figure : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, 2010–2016
Figure 1 : UNITED STATES MARKET FOR ADVANCED STRUCTURAL CARBONS BY TYPE, 2010
Figure 2 : PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS MARKET, 2011–2016
Figure 3 : GLOBAL ADVANCED STRUCTURAL CARBONS MARKET BY TYPE, 2010(TOTAL = $4.9 BILLION)
Figure 4 : GLOBAL STRUCTURAL CARBONS CONSUMPTION BY WORLD REGION, 2010
Figure 5 : SCHEMATIC OF MANUFACTURING PROCESS FOR SYNTHETIC GRAPHITE
Figure 6 : CRYSTALLINE STRUCTURE OF GRAPHITE
Figure 7 : REPRESENTATION OF CARBON-CARBON COMPOSITE MANUFACTURING PROCESS
Figure 8 : U.S. CARBON FIBER CONSUMPTION BY INDUSTRY SEGMENT, 2010 VS. 2016
Figure 9 : U.S. CARBON FIBER MARKET BY INDUSTRY, 2010 VS. 2016
Figure 10 : U.S. CONSUMPTION OF CARBON FOAM BY INDUSTRY SECTOR, 2010 VS. 2016
Figure 11 : U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, 2010 VS. 2016
Figure 12 : U.S. CARBON-CARBON COMPOSITES CONSUMPTION BY INDUSTRY TYPE, 2010 VS. 2016
Figure 13 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016
Figure 14 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016
Figure 15 : LEADING U.S. CARBON FIBER SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010
Figure 16 : LEADING U.S. CARBON FOAM SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010
Figure 17 : LEADING U.S. STRUCTURAL GRAPHITE SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010
Figure 18 : LEADING U.S. CARBON-CARBON COMPOSITE SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010
Figure 19 : COMPARISON OF ADVANCED STRUCTURAL CARBONS CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2010