Researchers at Washington University in St. Louis have developed a new process for producing carbon fibre using lignin, a by-product of paper pulping and biorefining, together with PAN and carbon nanotubes. The aim is to reduce both manufacturing cost and environmental impact while maintaining high mechanical performance.
Conventional carbon fibre production relies heavily on polyacrylonitrile (PAN), a petroleum-derived precursor that can account for up to 50% of total manufacturing cost. By adding lignin, the researchers were able to cut PAN use by half, reduce production costs by around 25% and substantially lower associated carbon emissions.
The main challenge was maintaining the tensile strength and elastic modulus required for industrial applications. To address this, the team introduced functionalised single-walled carbon nanotubes, which act as microscopic reinforcement and promote crystalline alignment during processing.
The manufacturing route consists of three main steps: preparation of the lignin-PAN precursor with nanotubes, wet spinning combined with tension-assisted heat treatment, and an optimised carbonisation stage. According to the researchers, this approach produces a highly aligned crystalline structure and improved mechanical properties.
The first target market identified by the researchers is automotive, although the technology could also have potential in aerospace, energy, wind turbines and other sectors where carbon fibre is used to reduce weight and improve structural performance.
The study therefore suggests a possible route to addressing two major limitations of carbon fibre production at the same time: high precursor cost and environmental impact, while making use of an abundant renewable industrial by-product.
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01 October 2026
