Plasma technology reduces energy demand in carbon fiber production

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In the entire manufacturing process (including both the stabilization and subsequent carbonization phases), the use of the new technology could result in a 60 percent reduction in energy consumption. "With the widespread implementation of the new plasma technology, carbon production could be brought back to Europe," the researchers hope. The more efficient production of carbon fibers also offers the automotive and aerospace industries the opportunity to develop lighter products that consume less fuel. Driven by this success, the researchers and their project partners are now continuing to work on process optimization. The next step is the construction of a functional oven utilizing the new plasma technology, enabling the start of the industrial pilot phase. The research project was carried out in collaboration with the University of Ulm, Dienes Apparatebau, and Fricke and Mallah Microwave Technology. It was funded by the German Federal Environmental Foundation (DBU).

The Plasma Expertise Promises Much More Innovation

To better understand the effect of plasma in the stabilization process of carbon fiber production, it is worth taking a closer look at the fundamental physical principles. Broadly speaking, plasma is known as a fourth state of matter. Just as solid ice melts and transitions from water (liquid) to steam (gaseous), plasma is formed when even more energy is introduced into the gas phase. Plasma actually plays an important but often unnoticed role in everyday life. The sun and lightning are natural forms of plasma. Processes for surface treatment, neon tubes, or welding techniques utilize controlled plasma. And yet, plasma still occupies a niche in research, despite its high energy density offering great potential for industrial use. Incidentally, the two researchers used microwave plasma for their new development. This is plasma that is sustained by electromagnetic waves in the gigahertz range—around two billion invisible oscillations per second.

As part of the Carbon Lab Factory Lausitz, a pilot plant for the production of sustainable, cost-effective and competitive carbon fibers will be built at the Guben site. (Image:Fraunhofer IAP / Kristin Stein)

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Date: 08.12.2025

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