Advanced composites are plastic structures (usually using thermoset resins like epoxy) reinforced by high performance fibers like carbon fiber or fiberglass. Because epoxy can be brittle, the aerospace industry saw a need for tougher composites made from high performance thermoplastics like PEEK (polyetheretherkytone). The challenge was one of blending PEEK, a solid at room temperature, with carbon fibers in a manner that allowed the component materials to be flexible enough to form intricately shaped parts.
Concordia's solution was commingling, the ability to blend flexible PEEK fibers intimately with carbon fibers producing a yarn that could be woven into a flexible fabric. Then the fabric was then fit into a complex mold and placed under heat and pressure to form a composite part. Concordia was issued three patents for their innovative process and entered into distribution agreements with BASF and CYTEC to market Concordia's material to Lockheed, McDonnell Douglas, Boeing and other aerospace manufacturers.
Concordia also perfected commingling processes for less expensive thermoplastic yarns, like nylon. The nylon/carbon version allowed Prince to develop a new line of tennis racquets called the Vortex. The material is also used in bicycle frames, hockey sticks and lacrosse sticks where its impact resistance is superior to many epoxies.