Mars Materials, NC State validate CO2-derived carbon fiber precursor

Mars Materials founders Kristian Gubsch (CTO), Aaron Fitzgerald (CEO) and Trey Sheridan (lead engineer) holding Hoigen-C. Source (All Images) | Mars Materials

Mars Materials Inc. PBC (Houston, Texas, U.S.), a public benefit corporation working to store captured CO₂ into everyday products, and a 2026 JEC Startup Booster finalist, has worked with textile experts at The Textile Innovation Engine of North Carolina and North Carolina State University (NC State) to successfully turn its CO₂-derived product into a high-quality raw material for making carbon fiber.

The joint study proved that Mars Materials’ carbon-negative product works exactly like the traditional chemicals made from oil and coal. In its very first test, the product met the strict standards needed for high-performance carbon fiber — the kind used in airplanes, transmission lines and cars.

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“This result keeps a promise we made to our investors and the industry,” says 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.”

PAN developed with NC State.

The testing was done by Dr. Januka Budhathoki-Uprety and her research team at the NC State Wilson College of Textiles. Researchers took Mars Materials’ product, called Hoigen-C, and turned it into polyacrylonitrile (PAN), the precursor for carbon fiber. They tested it and found it was chemically identical to the version made from oil and coal.

“The chemical structure and molecular weight are similar to commercial PAN,” explains 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.”

This validation opens a critical domestic supply line for major carbon fiber buyers like the U.S. military. The old, polluting way of making carbon fiber relies on a volatile global supply chain and creates toxic waste. Mars Materials’ way to PAN uses captured CO₂, is hydrogen cyanide-free and ensures a secure North American supply chain.

With the chemistry solved, the focus now shifts to spinning fiber and planning for mass production. Interested commercial partners and funders should contact Mars Materials to discuss partnerships.