In various high-performance sectors like wind energy, carbon fiber composites are indispensable due to their light weight and high-strength properties. However, the end-of-life management of carbon fiber waste poses a significant environmental challenge. Traditional disposal methods, including incineration and landfilling, are not sustainable. Recent advancements in carbon fiber recycling have fostered sustainable solutions across multiple industries.
The importance of carbon fiber recycling
Carbon fiber reinforced polymers (CFRP) are crucial for industries that require materials with exceptional strength-to-weight ratios. However, their production and disposal are energy-intensive processes. Recycling carbon fiber helps conserve resources and reduce the carbon footprint associated with manufacturing new materials.
Innovative recycling processes
Several innovative processes have emerged to address carbon fiber waste, turning it into valuable resources. Mechanical recycling, thermal recycling and chemical recycling are key methods. Each process involves breaking down carbon fiber composites to recover fibers that can be reused in various applications:
Mechanical recycling: Mechanical recycling involves physically breaking down carbon fiber composites into smaller pieces using advanced machinery. This process is energy-efficient because it does not use high temperatures. However, traditional methods like grinding and crushing can shorten the fiber lengths, reducing their quality and strength. Deeptech startup Fairmat has developed an innovative robotic system that mechanically cuts the fibers while preserving their mechanical properties, making them suitable for reuse.
Thermal recycling known as pyrolysis: Thermal recycling uses high temperatures to decompose the resin matrix in carbon fiber composites, leaving behind clean fibers. While effective, this method requires significant energy input and may release harmful emissions if not properly managed.
Chemical recycling known as solvolysis: Chemical recycling employs solvents to dissolve the resin matrix, separating the fibers without damaging their structure. This method is efficient and results in high-quality recycled fibers, although it involves complex chemical processes and significant chemical waste if not properly managed.
Broader industry impact
The impact of carbon fiber recycling extends beyond individual companies. Industry-wide adoption of recycling technologies can significantly reduce the environmental impact of various sectors, including wind energy. This supports global sustainability goals and enhances the economic viability of using recycled materials by reducing costs.
Fairmat has made significant strides in developing mechanical recycling processes. Established in 2020 by Benjamin Saada, Fairmat has collaborated with partners such as Hexcel, Dassault Aviation, Exel Composites and Tarmac Aerospace. These partnerships drive Fairmat’s mission of closing the loop on carbon fiber waste and making significant strides in sustainability.
Fairmat’s recycling process begins with the collection and segregation of carbon fiber waste from various sources. The waste materials, which can include prepregs, offcuts and end-of-life (EOL) products, are carefully segregated to identify those suitable for recycling. Upon arrival at Fairmat’s facilities, the collected waste undergoes further segregation and preprocessing. This step ensures that the materials are in optimal condition for recycling. Preprocessing treatments, such as cleaning and cutting, are applied to prepare the carbon fiber waste for the next stage.
Mechanical recycling is the primary method used by Fairmat. This involves proprietary cutting technologies and the use of advanced machinery, robotics and artificial intelligence (AI). Importantly, unlike traditional grinding or crushing, Fairmat’s proprietary cutting technology mechanically breaks down the carbon fiber composites into smaller pieces while preserving the mechanical properties of the fibers, making them suitable for reuse in high-performance applications. Robotic tools and AI enhance the precision and efficiency of this process, converting the carbon fiber components into CFRP (carbon fiber reinforced polymer) building blocks. This is a unique and sustainable technology that combines material science, data informatics and robotics, permitting the recycling of a broad range of carbon feedstocks (uncured and EOL products). This innovative process creates recycled carbon fiber that can be used for applications such as interior structural reinforcements, impact surfaces and exterior design finishings. By seamlessly integrating advanced recycled material both inside and outside products poised to enhance electronics, sporting goods, mobility and beyond, Fairmat is not only redefining industries but also setting new benchmarks for innovation and environmental stewardship.
Partnerships driving sustainability
Fairmat’s innovative recycling technology allows for the production of 100% recycled carbon composites that retain their strength and lightweight properties. By partnering with companies like Hexcel, Fairmat has established a 10-year agreement to recycle carbon fiber composite materials from Hexcel’s Salt Lake City facility for reuse in various commercial markets. Additionally, the partnership with Exel Composites focuses on recycling carbon fiber composite scrap from Exel’s plants in Finland, transforming it into high-performance CFRP chips using the proprietary cutting technologies described above.
Future directions
Despite the advancements, challenges remain in scaling up recycling processes and ensuring economic feasibility. Research and development efforts are crucial in overcoming these hurdles and improving recycling efficiency. Future directions include enhancing the quality of recycled fibers and developing new applications for recycled materials. Collaboration within the industry ecosystem is essential to maximizing impact.
Recycling carbon fiber is a vital component of the sustainability strategy across multiple high-performance industries. By transforming waste into valuable resources, the industry can significantly reduce its environmental footprint and move closer to achieving a circular economy.
Dr. Michael Gaultois is the Chief Scientific Officer of Fairmat, a deeptech startup that uses material science, AI and robotics to recycle carbon fiber composite and manufacture products. Before joining Fairmat in 2022, Michael led research at the interface of Materials Science and AI, developing novel methods and functional materials with applications in sustainability and energy. Michael has held numerous prestigious international fellowships, including a Fulbright International Science and Technology Fellowship at the University of California Santa Barbara, a Marie Skłowdowska–Curie Fellowship at the University of Cambridge, and a Ramsay Memorial Fellowship at the University of Liverpool.
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