Thread produces carbon fiber using a proprietary process that converts asphaltenes from oil‑sand bitumen into a high‑performance material. Their method cuts production costs by more than 50%, reduces emissions up to 90%, and can expand global supply tenfold, delivering fiber that is up to ten times stronger than steel by weight while being lightweight, corrosion‑resistant, and fire‑tolerant. The company operates a 10,000 sq ft pre‑commercial facility in Edmonton to demonstrate scalable manufacturing.
Funding
Funding not disclosed
Founders
Product
Problem
Conventional carbon fiber production is energy‑intensive, costly, and emits large amounts of greenhouse gases, limiting its adoption in cost‑sensitive, high‑performance sectors such as transportation and power generation.
Solution
Thread has developed a proprietary manufacturing process that converts the naturally occurring asphaltene molecules in oil‑sand bitumen into carbon fiber. By leveraging this feedstock, the process cuts production costs by more than 50% and reduces emissions by up to 90% compared with traditional methods. The resulting fiber exhibits a strength‑to‑weight ratio up to ten times that of steel and stiffness up to five times greater than aluminum, while also offering corrosion resistance, high temperature tolerance, and permanent carbon sequestration. Thread operates a 10,000 sq ft pre‑commercial facility in Edmonton to demonstrate scalable production and to supply carbon fiber that meets emerging performance requirements for next‑generation applications.
Target Audience
Primary customers are manufacturers of aerospace, automotive, rail, and high‑power density equipment seeking lightweight, high‑strength materials with lower environmental impact.
Features
- Proprietary conversion of asphaltene‑rich bitumen into carbon fiber, enabling >50% cost reduction
- Production emissions lowered by up to 90% relative to conventional carbon fiber processes
- Mechanical performance: up to 10× steel strength‑to‑weight ratio and up to 5× aluminum stiffness
- High temperature resistance up to 1200 °C with low thermal expansion
- Intrinsic corrosion and fatigue resistance for extended service life
- Permanent carbon sequestration in a non‑toxic, chemically stable fiber form
- Demonstrated commercial scalability in a 10,000 sq ft pre‑commercial plant