Recycling of high-performance thermoplastic composites

For many applications, especially in mobility, reducing weight is an important driver to reduce energy consumption. The use of thermoplastic composites (TPCs) replacing metal components is a promising way to reduce product weight without compromising mechanical performance. This way, composites contribute considerably to CO₂ savings in mobility applications, but improved recycling technologies are needed to comply with regulations regarding the use of recycled materials while meeting product requirements. We present a versatile and efficient recycling technology capable of transforming a wide range of TPC waste streams into high-performance secondary materials, by as much as possible retaining fiber length during recycling. Compatible input materials include shredded TPC flakes, polymer scrap, recovered or recycled fibers, shredded packaging waste, virgin polymers and additives, and TPC tape waste, and the technology can recycle different combinations of waste streams to achieve desired composition and mechanical performance. In this way, glass and carbon fibers reclaimed from pyrolyzed thermoset composites can be processed together with recycled polymers to produce recycled TPCs to replace virgin materials. We will show several case studies from different applications, including the scale-up to pilot scale level (60 – 80 kg/h) and the mechanical evaluation of the recycled materials, compared to virgin benchmark materials. In particular, results from the Horizon Europe project GIANCE will be highlighted. GIANCE focuses on developing affordable, eco-friendly, lightweight, and recyclable materials based on graphene and related substances.