Multi-level Circular Process Chain for Carbon and Glass Fibre Composites

Each year about 110.000t of carbon fibre composite parts and 4.500.000t of glass fibre composites are used. 98% of these parts end up in landfills at the end of their life. To address this problem the MC4 project aims at establishing a multi-level circular process for carbon and glass fibre composite. Multi-level means that processes will be developed for short-term implementation with immediate impact and for the longer term with a wider impact on industry. Carbon and glass fibre have substantially different costs and the project takes this into account by developing economically feasible procedures that are based on chemical matrix/fibre separation for carbon fibre and on a new type of resing for the direct re-use of the composite for glass fibre. Quality grading of the recycled material will be a key element to ensure a proper use in the different domains. Within the supply chain investigated in the project the goal is to achieve a recycling rate of at least 60%.

As an additional benefit, the project will enable European material manufacturers to develop their own, patented processes for manufacturing of recycled material. Currently, 80% of the manufacturing of virgin carbon and glass fibre is taking place outside of Europe and the manufacturing technologies used inside of Europe are often licensed from foreign countries.

MC4 puts particular emphasis on the design and manufacturing of best practice examples of parts made from recycled materials. For five different domains, including automotive, aerospace, sports equipment, boats and urban furniture, composite products will be manufactured, with the aim of demonstrating the use of recycled material and enhancing the demand side for recycled material in the different domains.

The consortium includes process developers, material manufacturers and SME end users, who manufacture composite parts. It covers the whole value chain and thus enables the creation of real circular process for composites.