Thermoplastic composites reinforced with carbon fibres are widely used in technical sectors, generating an increasing need for efficient recycling routes that reduce waste and recover high-value raw materials. Current recycling processes, such as pyrolysis, can recover chopped carbon fibres of different lengths, but these fibres are usually limited to low-performance nonwoven fabrics with restricted applications.
This limits the potential reuse of recycled carbon fibres in advanced composites, where higher mechanical performance and more structured textile formats are required.
To address this need, researchers from the Technical Fibres and Textile Materials research group at AITEX have developed a process to convert recycled chopped carbon fibres into yarns, tapes and fabrics suitable for manufacturing thermoplastic composites with improved mechanical properties.
The technology is based on the adaptation of textile processes to revalue chopped carbon fibres obtained from recycled fibre-reinforced composites. By using technologies such as carding, staple fibre spinning and weaving, the process enables the production of recycled carbon fibre yarns and fabrics with controlled and homogeneous properties.
These textile formats can then be used as reinforcement materials in thermoplastic composites, providing better mechanical performance than conventional nonwoven products made from recycled fibres. This approach expands the potential applications of recycled carbon fibres in technical sectors requiring lightweight, resistant and more sustainable composite materials.
The process has now been developed and has been carried out on a pilot scale.
Benefits:
- Revalorisation of recycled chopped carbon fibres.
- Production of yarns, tapes and fabrics from recycled fibres.
- Improved mechanical properties compared with nonwoven formats.
- Lower cost than virgin carbon fibre production.
- Reduced waste and energy consumption.
- Support for circular economy in composite materials.
The represented institution is looking for a collaboration that leads to commercial exploitation of the presented invention.
Institution: AITEX
TRL: 4-5
Protection Status: Know-how
Contact: Begoña Iborra | biborra@viromii.com