US Automotive Carbon Fiber Market to Reach $2.0 Billion by 2035
The US Automotive Carbon Fiber Market was valued at $2.0 billion in 2025 and is projected to reach $3.2 billion by 2035, expanding at a 5.0% CAGR from 2026 to 2035. A major market driver is the increasing use of lightweight materials in vehicle structures. The U.S. Department of Energy identifies carbon fiber and polymer composites as advanced materials that can reduce vehicle body and chassis weight. DOE also notes that carbon fiber composites can provide substantial mass reduction in vehicle components, supporting their application in lightweight automotive structures.
Browse the full report description of “US Automotive Carbon Fiber Market Size, Share & Trends Analysis Report, By Raw Material Type (PAN, Pitch), By Fiber Type (Virgin, Recycled), By Modulus (Standard, Intermediate, High), By Product Type (Continuous, Long, Short Carbon Fiber), By Application (Composites, Non-Composites), By End-User (Aerospace & Defense, Automotive, Wind Energy, Pipe, Pressure Vessels, Sporting Goods, Construction & Infrastructure, Medical & Healthcare, Marine), Forecast Period (2026-2035)” at https://www.omrglobal.com/industry-reports/us-automotive-carbon-fiber-market
The U.S. electric-vehicle market provides an additional application base for lightweight composite materials. According to the Alliance for Automotive Innovation, 1,511,549 EVs were registered in the U.S. during 2025, while total light-duty vehicle sales increased 2.2% year over year. The combination of electrified powertrains and increasing requirements for efficient vehicle structures supports continued development of lightweight composite components for U.S. vehicle manufacturing.
Recycled Carbon Fiber Segment to Witness Strong Growth
The recycled carbon fiber segment is gaining importance in the U.S. automotive carbon fiber market as domestic research increasingly focuses on recovering carbon fibers from composite waste and converting them into new vehicle materials. In its FY2025 commercialization projects, the U.S. Department of Energy identified a project focused on manufacturing new composites using domestically sourced recycled carbon fiber from existing waste streams, including automotive scrap. The project targets more than 75% reductions in embodied energy and cost for the recycled carbon-fiber feedstock compared with conventional material pathways.
U.S. federal research activity is also addressing the use of recycled carbon fiber in structural automotive components. DOE's Vehicle Technologies Office has supported projects focused on transforming carbon-fiber-reinforced polymer waste into recyclable structural automotive components, while its 2025 research program included projects on low-cost composites from recycled materials for lighter vehicles, carbon fibers produced from waste materials, and sustainable circular manufacturing of automotive composites. These initiatives indicate that recycling technologies are becoming an active area of U.S. automotive composite development, particularly for reducing material waste and improving the economics of carbon-fiber-intensive vehicle components.
Recent Developments
- In January 2026, Toray announced a carbon-fiber-reinforced plastic bonding technology designed to improve the recovery and reuse of carbon-fiber composite materials. The technology supports circular composite manufacturing and has relevance to automotive applications where reducing composite waste and improving material utilization are important. Toray Composite Materials America operates U.S. carbon-fiber manufacturing facilities and serves the Transportation & Automotive market.
- In January 2024, Toray Composite Materials America commissioned a $15 million upgrade at its Decatur, Alabama carbon-fiber facility, doubling production capacity for TORAYCA T1100 carbon fiber. The expansion strengthens U.S. carbon-fiber manufacturing capacity and supply availability, supporting growing demand for advanced composite materials, including applications in transportation and automotive markets.
Market Coverage
- The market numbers available for 2025-2035
- Base year- 2025
- Forecast period- 2026-2035
- Segment Covered-
- By Raw Material Type
- By Fiber Type
- By Modulus
- By Product Type
- By Application
- By End User
- Competitive Landscape – Toray Industries, Inc.; Hexcel Corporation; Teijin Limited; SGL Carbon SE; Syensqo.
Key questions addressed by the report.
- What is the market growth rate?
- Which segment and region dominate the market in the base year?
- Which segment and region will project the fastest growth in the market?
- Who is the leader in the market?
- How are players addressing challenges to sustain growth?
- Where is the investment opportunity?
US Automotive Carbon Fiber Market Report Segment
By Raw Material Type
- PAN
- Pitch
By Fiber Type
- Virgin
- Recycled
By Modulus
- Standard
- Intermediate
- High
By Product Type
- Continuous Carbon Fiber
- Long Carbon Fiber
- Short Carbon Fiber
By Application
- Composites
- Non-Composites
By End-use Industry
- Aerospace & Defense
- Automotive
- Wind Energy
- Pipe
- Pressure Vessels
- Sporting Goods
- Construction & Infrastructure
- Medical & Healthcare
- Marine
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