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A Sustainable Route for CF/PA6 Composite Waste: From Scrap to Solutions
Larissa Stieven Montagna1, Guilherme Ferreira de Melo Morgado1, Luis Felipe de Paula Santos2
1Polymer and Biopolymer Technology Laboratory (TecPBio), Federal University of São Paulo (UNIFESP), 330 Talim St., 12231-280 São José dos Campos, Brazil.
ACS Omega
|June 8, 2026
Summary
Recycling carbon fiber reinforced thermoplastics (CFRTP) is challenging but feasible. This study demonstrates a sustainable mechanical recycling method for automotive composite scrap, yielding a viable secondary product with good adhesion but reduced flexural strength.
Area of Science:
- Materials Science
- Composite Materials Engineering
- Sustainable Manufacturing
Background:
- Recycling carbon fiber reinforced thermoplastics (CFRTP) presents significant challenges due to waste stream variability and end-use application limitations.
- The mechanical and physicochemical properties of recycled composites often restrict their use to non-structural components.
- Sustainable recycling routes are crucial for managing preconsumer waste from industries like automotive manufacturing.
Purpose of the Study:
- To propose and evaluate a sustainable mechanical recycling process for primary carbon fiber (CF)/polyamide 6 (PA6) composite scrap from the automotive sector.
- To investigate the feasibility of producing reprocessed laminates with desirable properties from this waste stream.
- To assess the thermal, mechanical, and morphological characteristics of the recycled composite materials.
Main Methods:
- Preconsumer CF/PA6 composite blanket scrap was cut into geometric shapes (squares, triangles) of two sizes (small: ~5 cm; large: ~10 cm).
- The shaped scraps were hot compression molded into four reprocessed laminates.
- Laminates were analyzed using ultrasound inspection, acid digestion for volume fractions, differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), interlaminar shear strength (ILSS), flexural strength, Izod impact strength, and fracture surface morphology.
Main Results:
- Reprocessed laminates exhibited superior interlaminar shear strength (ILSS) and satisfactory adhesion between the carbon fiber reinforcement and the polyamide 6 matrix.
- The random orientation of carbon fibers significantly reduced flexural performance.
- Laminates with smaller, triangular patches (Laminate C) demonstrated enhanced impact resistance due to their crack propagation barrier effect.
Conclusions:
- Mechanical reprocessing of thermoplastic composite scraps is a feasible and satisfactory method for creating secondary products.
- The study successfully demonstrated a sustainable route for recycling automotive composite waste.
- While flexural properties were compromised, the recycled material showed potential for applications requiring good impact resistance and adhesion.
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