Why Process Innovation May Decide the Future of Carbon Fiber Cars

A new high-temperature release film could smooth carbon fiber production and push composites deeper into mainstream vehicles

2 Feb 2026

The race to lighten the modern car is no longer just about stronger fibers or smarter resins. It is about how smoothly those materials move through the factory.

Toray’s latest advance focuses on a small but critical piece of that puzzle: release film. The company has introduced what it calls the industry’s first high-temperature polypropylene release film designed specifically for automotive composite processing. It may sit quietly in the background, but its impact could ripple across production lines.

Release films separate composite parts from molds during curing. If they fail, surface defects and inconsistencies follow. Toray’s new film is engineered to withstand temperatures up to 160°C, helping reduce blemishes and improve uniformity during molding. For automakers eyeing carbon fiber beyond niche sports cars, that kind of reliability matters.

The auto industry has long admired composites for their strength-to-weight ratio. Yet scaling them for high-volume programs remains difficult. Production repeatability, cycle times, and yield rates often stand in the way. A small improvement in processing can translate into meaningful gains when multiplied across thousands of vehicles.

That urgency is growing. Electric vehicles carry heavy battery packs, adding mass that engineers must offset elsewhere. Lightweight materials offer one solution, but only if they can be produced consistently and economically. Manufacturing refinements like advanced release films quietly lower the risk.

Market forecasts continue to project steady growth in automotive composites, driven by efficiency targets and expanding EV lineups. Still, carmakers remain cautious. Cost pressures, qualification timelines, and supply chain complexity demand practical answers, not just performance promises.

Toray’s move reflects a broader shift across the composites sector. Innovation is no longer confined to breakthrough fibers. Increasingly, it is found in process tweaks that shave minutes off cycle times and reduce scrap.

Challenges remain, from recycling hurdles to production complexity. But each incremental improvement strengthens the case.

In the end, the future of automotive composites may hinge less on what they are made of and more on how easily they can be made.