Mars Materials, Inc. PBC™, a public benefit corporation focused on storing captured carbon dioxide in everyday products, has announced a major breakthrough in carbon fiber manufacturing. In collaboration with textile and materials experts at The Textile Innovation Engine of North Carolina and North Carolina State University (NC State), the company has successfully validated a CO₂-derived raw material suitable for high-performance carbon fiber production.
The joint research confirms that Mars Materials’ carbon-negative precursor performs on par with conventional petroleum- and coal-based chemicals currently used in carbon fiber manufacturing. In its first production trial, the material met the stringent performance requirements demanded by applications such as aerospace components, automotive structures, and power transmission systems.
“This result keeps a promise we made to our investors and the industry,” said Aaron Fitzgerald, CEO and Co-Founder of Mars Materials. “We proved we can make carbon fiber from the air without losing any quality. Just as we did with our water-soluble polymers, getting it right on the first try allows us to move faster. We can now focus on scaling up production to accelerate bringing manufacturing of this critical material back to the U.S.”
Scientific Validation at NC State
The validation work was led by Dr. Januka Budhathoki-Uprety and her research team at the Wilson College of Textiles, NC State. Researchers converted Mars Materials’ proprietary CO₂-derived product, Hoigen-C, into polyacrylonitrile (PAN)—the essential precursor used in all carbon fiber manufacturing.
Comprehensive testing confirmed that the CO₂-based PAN was chemically identical to conventional PAN produced from fossil-based feedstocks.
“The chemical structure and molecular weight are similar to commercial PAN,” said Dr. Ericka Ford, Associate Professor at NC State. “It is definitely a drop-in because you can add in any co-monomer that you want. For carbon fiber manufacturers looking to reduce their carbon footprint, this validates a viable pathway.”
Strategic Implications for Supply Chains and Sustainability
This breakthrough establishes a potential domestic and carbon-negative supply chain for carbon fiber—a strategic material widely used by sectors such as defense, aerospace, automotive, and infrastructure. Traditional carbon fiber production depends on volatile global supply chains and generates toxic by-products. In contrast, Mars Materials’ process uses captured CO₂, eliminates hydrogen cyanide from production, and significantly reduces environmental impact.
The validation is particularly significant for large institutional buyers, including the United States military, where secure, resilient, and domestic sourcing of advanced materials is critical.
Next Steps Toward Commercialization
With the chemistry successfully validated, Mars Materials will now focus on fiber spinning trials and large-scale manufacturing planning. The company has invited commercial partners, manufacturers, and investors to engage in discussions aimed at accelerating industrial-scale production and deployment.