Ames Researchers Created Low-Cost Biobased Carbon Fiber
The research team aims to scale production of carbon fiber using lignin to lower industrial costs.
Updated on Oct. 14, 2026 in Materials Science
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Iowa State University researchers have developed a method to produce carbon fiber from softwood kraft lignin and aqueous bio-oil. The project, which is currently in the research stage, seeks to provide a lower-cost alternative to petroleum-based precursors.
Why it matters
Current carbon fiber manufacturing relies on high-cost petroleum-based precursors that restrict widespread industrial adoption. This research aims to reduce these costs and expand the material's viability across sectors.
The biobased fiber achieves a tensile strength of 2.45 gigapascals and a tensile modulus of 236 gigapascals, with manufacturing costs kept below $5 per pound. Stabilization time for the spun fiber is reduced to two to four hours through a thermo-mechanochemistry process.
The players
Iowa State University
A public research university in Ames with a strong focus on engineering and material science innovation.
National Science Foundation
A U.S. government agency that supports fundamental research and education in all non-medical fields of science and engineering.
The details
The process uses a thermo-mechanochemistry method, where lignin is heated and subjected to mechanical stress to physically alter its chemical structure. Scientists also apply watery bio-oil to transform non-softening lignin into melt-spinnable precursors. This approach simplifies the production of fibers that are traditionally costly to stabilize and synthesize.
Timeline
Research into lignin-based carbon fiber production began in the 1960s.
The research group began investigating biobased carbon fiber production in 2015.
The National Science Foundation grant will support the project for four years.
The Tech Race
This project moves toward renewable alternatives in a field that has historically relied on expensive petroleum-based polyacrylonitrile precursors. Researchers are now working to transition from batch-based laboratory results to a continuous commercial production model.
The development targets industrial manufacturers who currently face high material costs for carbon fiber components. Practical application remains in the research stage, with full-scale commercial availability dependent on the success of the transition to continuous production systems.
The takeaway
The research team is working to overcome the cost barriers associated with traditional carbon fiber by utilizing low-cost wood byproducts. Stakeholders should monitor the four-year progression of the project for updates on the viability of continuous commercial-scale production.
Further reading
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