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Discontinuous Highly Aligned Carbon Fibre Tapes Combined with Bio-Based Polyamide 11
Christian Brauner1, Florian Givel1, Julian Kupski1
1Institute of Polymer Engineering, FHNW University of Applied Sciences and Arts Northwestern Switzerland, Klosterzelgstrasse 2, 5210 Windisch, Switzerland.
Polymers
|August 13, 2026
Summary
This study demonstrates how aligned recycled carbon fibres (rCFs) with bio-based polyamide 11 create sustainable, high-performance composites. Optimized fibre alignment significantly enhances mechanical properties for lightweight applications.
Area of Science:
- Materials Science
- Composite Materials
- Sustainable Engineering
Background:
- Increasing availability of recycled carbon fibres (rCFs) presents opportunities for sustainable composites.
- Discontinuous nature of rCFs necessitates efficient alignment and consolidation techniques.
- Bio-based polymers offer a sustainable alternative to conventional matrix materials.
Purpose of the Study:
- To manufacture highly aligned discontinuous rCF tapes using recycled carbon staple fibres and bio-based polyamide 11 (PA11).
- To investigate the effect of fibre content on the microstructure and mechanical performance of the resulting composites.
- To evaluate the correlation between fibre architecture and mechanical properties.
Main Methods:
- Textile-based processing route for fibre alignment.
- Compression moulding for laminate fabrication.
- Characterization of fibre volume content (FVC), fibre orientation, and mechanical properties (tensile, compression, shear).
- 2D mesoscopic image analysis for fibre orientation distribution.
Main Results:
- Achieved FVC up to 56.72 vol.% for 70 wt.% rCF material.
- Significant increase in tensile stiffness (48.1 GPa) and strength (866 MPa) with higher fibre content.
- Pronounced preferential fibre orientation (69% within ±10°).
- Alignment coefficient (η0) correlated well with tensile modulus, highlighting the importance of fibre architecture.
Conclusions:
- The combination of bio-based PA11 and oriented rCFs offers a promising route to sustainable lightweight composites.
- Textile-based alignment technologies are effective for processing discontinuous rCFs.
- Optimized mesoscopic fibre architecture is crucial for enhancing composite mechanical performance.
Keywords:
3D printingadditive manufacturingaligned discontinuous fibresbio-based polyamide 11composite taperecycled carbon fibresustainable compositesMore Related Videos
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