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Composite materials are engineered combinations of two or more distinct materials, merging their individual properties to create a new material with enhanced characteristics. Typically composed of a reinforcing phase (like fibers or particles) embedded within a matrix (often a polymer, metal, or ceramic), composites leverage the strengths of each component to achieve superior strength, stiffness, lightness, or other desirable attributes. Their versatility extends across industries, from aerospace and automotive to construction and sports equipment, where their tailored design and exceptional properties offer solutions for high-performance applications.
Recycling in composites manufacturing is an evolving endeavor aimed at addressing sustainability challenges. Unlike traditional materials, composites often pose recycling complexities due to their multi-component nature. However, innovative techniques are emerging to tackle this issue. Methods like pyrolysis, mechanical recycling, and chemical processes are being developed to efficiently recover valuable components from composite waste, such as fibers or matrix materials.
Named a technology partner for the three-year FCVGen2.0 project, Cygnet’s role is to optimize the composites recycling machinery and process for EOL composite hydrogen tank reclaim and reuse.
Roctool aims to upgrade composites manufacturers with dynamic temperature management for thermocompression, thermoforming and vacuum molding processes.
The EROS project, with the participation of Aimplas and the Institute of Ceramic Technology (ITC) is working to develop new recycling process to recover and repurpose composite materials from wind and aeronautic industries.
Scientists from Japan develop cellulose nanofiber-carbon fiber composite films with high in-plane heat conductivity to assist in heat dissipation in electronic devices.
Companies like Syensqo, Weav3D, Toyota, CompositeEdge and Teijin Automotive Technologies are recognized for their composites-forward approaches to more sustainable, energy-efficient automotive efforts.
DLR has developed a novel approach to produce thermoplastic impregnated fibers for lower cost versus current slit-tape materials.
Japan’s premiere single-seater race series confirms hybrid composite parts for SF23 chassis as part of Next 50 plan.
Though its recent SuperTruck project used CFRP to slash over 3,200 lb, Volvo says it needs lower cost materials like recycled carbon fiber.
Compared to legacy materials like steel, aluminum, iron and titanium, composites are still coming of age, and only just now are being better understood by design and manufacturing engineers. However, composites’ physical properties — combined with unbeatable light weight — make them undeniably attractive.
Alex Edge, sales and business development manager for recycler ELG Carbon Fibre (Coseley, U.K.), says his company’s recycled carbon fiber (RCF) products can offer from 30 to 40 percent cost savings vs. virgin carbon fiber (VCF). Tim Rademacker, a managing director at competitor CFK Valley Recycling (Stade, Germany) cites savings of 20 to 30 percent.
