Published: March 2026
Estimated reading time: 4 minutes
A Milestone That Reduces Certification Risk—Not Just a Material Upgrade
In aerospace composites, performance alone is not enough.
Materials must pass through one of the most demanding barriers in the industry:
certification acceptance.
Toray Composite Materials America has announced that its next-generation 3960 prepreg system has achieved NCAMP qualification, with design allowable data now published in the official database.
At first glance, this appears to be another material milestone.
In practice, it addresses a much larger issue:
reducing the time, cost, and uncertainty associated with material certification in aerospace programs.
What NCAMP Qualification Actually Changes
For aerospace manufacturers, NCAMP (National Center for Advanced Materials Performance) qualification is not just validation.
It provides:
- standardized material data
- FAA-recognized allowables
- reduced need for redundant testing
Without this, OEMs and Tier suppliers typically must:
- run extensive internal qualification programs
- generate their own allowables
- absorb significant cost and time delays
With NCAMP-qualified materials:
The material is already “trusted” at a regulatory level.
This directly impacts:
- program timelines
- certification pathways
- supply chain decisions
The 3960/T1100 System: Performance Built for Primary Structures
Toray’s 3960 prepreg system is built around TORAYCA™ T1100 IM+ carbon fiber, targeting high-performance structural applications.
Key characteristics include:
- high toughness
- strong tensile performance
- reliable hot/wet properties
These properties are critical for:
- aircraft primary structures
- launch vehicle components
- satellite systems
From a design standpoint, this positions the material for:
- load-bearing structures
- fatigue-critical applications
- long service life environments
Five-Batch Qualification: Why It Matters
The NCAMP qualification was based on five-batch testing, which is significant.
In composite materials:
- variability between batches can affect performance
- consistency is as important as peak strength
Five-batch qualification demonstrates:
- process stability
- repeatability across production runs
- reliability at scale
In aerospace terms, this is what separates “lab material” from “production material.”
NMS 397 Specification: Standardization Across Programs
Toray, working with NCAMP, also developed NMS 397, a material and process specification accepted by both:
- FAA
- EASA
This provides:
- a standardized procurement route
- defined processing conditions
- alignment across global certification bodies
For manufacturers, this simplifies:
- supplier qualification
- documentation
- compliance
AFP Data: A Step Toward Automated Manufacturing Acceptance
One of the more notable aspects of this qualification is the inclusion of Automated Fiber Placement (AFP) data.
A three-batch allowable dataset was generated under the U.S. Air Force Research Laboratory (AFRL) MASC program.
This represents:
one of the first publicly available allowable datasets tied directly to an automated composite manufacturing process.
This is important because AFP introduces variables such as:
- tow placement accuracy
- thermal input control
- defect formation (gaps, overlaps)
By establishing allowables linked to AFP processing, the industry moves closer to:
- validating automated manufacturing methods
- reducing reliance on manual layup
Manufacturing Perspective: Why This Changes Material Selection
From a production standpoint, material selection in aerospace is rarely driven by performance alone.
Key considerations include:
- certification pathway
- processing compatibility
- supply chain reliability
The 3960/T1100 system now addresses all three:
- qualified allowables available
- compatible with automated processes (AFP)
- supported by established production capacity
This reduces friction in:
- program adoption
- scaling production
- transitioning to new materials
Broader Industry Context: Speed Matters More Than Ever
Aerospace programs are under increasing pressure to:
- reduce development cycles
- lower costs
- maintain performance
Traditional material qualification can take years.
By providing:
- pre-qualified data
- standardized specifications
Toray’s approach helps compress that timeline.
The advantage is not just material performance—it is time to certification.
Application Scope: From Aircraft to Space Systems
The qualified prepreg system is positioned for:
- primary structural components
- secondary structures
- high-performance aerospace assemblies
Applications include:
- fuselage structures
- wing components
- satellite frames
- launch vehicle structures
This reflects a broader trend:
- materials are being designed not just for performance
- but for multi-platform applicability
Final Insight: Qualification Is the Real Barrier in Aerospace Composites
In many industries, innovation is limited by material capability.
In aerospace, the limiting factor is often different:
qualification and certification.
Toray’s NCAMP qualification of the 3960 prepreg system addresses this barrier directly.
It does not just introduce a new material.
It provides a ready-to-use, certifiable solution.