High-Performance PA6 Composites Reinforced with Recycled Aramid Fibers from Firefighter Protective Clothing

The recycling of technical textile waste represents a major challenge due to the complex and multilayered structure of these materials. Firefighter protective clothing, mainly composed of high-performance aramid fibers combined with polymeric membranes and auxiliary textile components, is commonly landfilled or incinerated at the end of its service life, resulting in a significant environmental impact. This work utilized recycled aramid-rich textile waste obtained from end-of-life firefighter protective clothing as reinforcement for polyamide 6 to develop high-performance thermoplastic composites within a circular economy framework. Composites containing 15, 30, 45, and 60 wt.% of recycled textile waste were manufactured by melt compounding followed by injection molding. In addition, a selected formulation containing 30 wt.% reinforcement was compatibilized using an amino-functional silane to improve interfacial adhesion. The materials were systematically characterized in terms of tensile properties, thermal behavior, thermomechanical performance, water uptake, flammability, colorimetric properties, and fracture morphology by field emission scanning electron microscopy. The results revealed a pronounced increase in stiffness and thermomechanical stability, with tensile strength increasing from approximately 65 MPa for neat PA6 up to 78 MPa at 30 wt.% reinforcement, and elastic modulus exceeding 5000 MPa at high reinforcement contents. An optimal balance between mechanical performance and ductility was achieved at 30 wt.% reinforcement, while higher contents enabled a substantial extension of the service temperature range, with HDT values increasing from 55 °C for neat PA6 up to 173 °C for highly reinforced systems. FESEM analysis confirmed improved interfacial adhesion in silane-compatibilized systems, explaining the enhanced mechanical and thermomechanical behavior. Furthermore, the incorporation of recycled aramid-rich textile waste led to a significant improvement in flame retardancy, enabling UL-94 V-0 classification at 30 wt.% reinforcement and above, without the use of additional flame-retardant additives, enabling UL-94 V-0 classification without additional flame-retardant additives. Overall, this study demonstrates the technical feasibility and high added-value potential of valorizing firefighter protective clothing waste into advanced PA6-based composites with enhanced mechanical, thermal, and fire-resistant properties, providing a sustainable route for the valorization of high-performance textile waste.