Alliance targets recycled carbon fibre composites

Industry partners and members of the European Composites Circular Alliance (ECCA) are collaborating to accelerate the development of high-value composite materials produced from recycled carbon fibre.

The initiative, involving James Cropper Advanced Materials (JCAM) and Hexcel through the ECCA’s Aerospace & Defence working group, aims to support performance and circularity across the aerospace, automotive and wider mobility sectors. The use of these advanced composites is growing but recycling challenges are significant.

JCAM’s products include substrates and components for hydrogen electrolysis and fuel cells, and industry-leading innovations in moulded fibre packaging. Customers are in markets from luxury retail to renewable energy. Hexcel claims to be the world’s largest producer of aerospace carbon fibre.

Demanding applications

ECCA is focused on enabling the use of recovered or recycled materials while maintaining the structural performance required for demanding applications. Improving fibre utilisation and ensuring consistent performance are seen as key factors in scaling circular solutions for high-value composites.

The collaboration between JCAM and Hexcel centres on the use of Unimat materials enabled by James Cropper’s Vectis aligned fibre technology. The companies say the objective is to develop enhanced recovery composite materials using recycled carbon fibre that can deliver meaningful structural performance in demanding environments.

Advancing composite materials derived from recycled fibre for aerospace and defence applications is a core ECCA objective. Achieving the right balance between performance, processability and efficient material utilisation is considered essential.

Wider benefits

According to David Tilbrook, senior technical fellow at Hexcel, improved fibre alignment addresses lightweighting and fuel burn reduction. ‘Fuel accounts for over 90% of an aircraft’s lifetime emissions and up to 30% of airline operating costs, so weight reduction is a key environmental and economic driver.

Increasing the value of composites using recycled fibres addresses exactly the kind of challenge ECCA aims to solve by promoting industry wide collaboration.’

Andy Walton, md of JCAM, says the alliance provides a platform for accelerating progress. ‘ECCA provides the framework for industry-wide collaboration and working with Hexcel within that framework allows us to accelerate learning and development in a way that benefits the wider composites ecosystem.’