MCAM Unveils New High‑Strength Carbon‑Fiber Thermoplastics for Metal Replacement

MCAM, an operating unit of Mitsubishi Chemical Holdings Group, has expanded its structural thermoplastic portfolio with new resin formulations tailored for the medical, oil & gas, aerospace, automotive and recreation markets. Launched two years ago, MCAM brings together the expertise of Switzerland’s Quadrant AG – specialists in glass‑mat thermoplastic composites – and Piper Plastics Inc., a former injection molder turned compounder known for its carbon‑fiber thermoplastics, KyronMax.

The KyronMax family leverages MCAM’s proprietary short‑carbon‑fiber technology, delivering the strongest moldable polymers available and enabling seamless replacement of steel in structural components. “We began with high‑temperature engineering thermoplastics and have since expanded to general‑purpose grades such as polypropylene, nylon and polycarbonate,” explains Dave Wilkinson, MCAM technology director. “If a customer needs nylon 66 that outperforms any market alternative, or a polycarbonate that offers superior strength, we can deliver it. Our goal is to meet each customer’s exact specification rather than impose a limited set of solutions.”

MCAM’s research has pushed tensile strength to 60,000 psi (414 MPa) – a benchmark rarely seen in the industry. These compounds are engineered for ease of use and excellent injection‑moldability. Wilkinson highlights the growing demand for metal replacement in automotive OEMs’ lightweighting and sustainability programs: “When components are lighter, the vehicle consumes less fuel, resulting in a significant CO₂ reduction.”

Beyond raw strength, KyronMax technology supports the production of highly complex parts that retain the mechanical performance of metal while providing the added benefits of thermoplastic processing.

At the heart of MCAM’s innovation is a 100,000‑sq‑ft North American Research & Development Technology Center that consolidates four former facilities into a single, vertically integrated operation. “We process raw carbon fiber from spool to finished part under one roof—chopping, compounding, molding and machining—all while offering our customers the flexibility to receive raw materials, molded parts, or anything in between,” says Wilkinson.

With 12 injection‑molding machines ranging from 20 to 700 tons, the center accommodates a wide spectrum of part sizes and complexities. MCAM’s global network of technical centers also allows customers to transfer molds across regions, ensuring consistent quality and rapid time‑to‑market worldwide.