Formosa Plastics Corp. (Taipei City, Taiwan) has collaborated with Taiwan Textile Research Institute (TTRI) (Taipei City) to develop an intermediate recycled carbon fiber-reinforced polycarbonate (PC) thermoplastic composite material. State-of-the-art PC fiber spinning technology combines a dry hybrid nonwoven technology combined with recycled carbon fiber (rCF). This combination could be post-consumer recycled PC and flame-retardant PC as well. PC fiber represents the polymer matrix for impregnation and consolidation, which means the addition of extra matrix resin is no longer necessary.

This novel material offers recycling and reshaping characteristics. It is lightweight, strong and meets customer requirements for various applications, such as consumer electronics and sporting goods. It enables the manufacture of complex shapes in a thermal pressing step, or combination of sheet forming and injection molding minus further steps for the production of parts. This can help reduce cycle time, manufacturing cost and CO₂ emissions. It also has a positive effect on the life cycle assessment of products.