Innovative Recycling Method for Carbon Fiber : Researchers from the Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI have developed a technology that makes it possible to reclaim continuous carbon fibers from composite materials — without diminishing material quality.
In a major advancement for sustainable materials engineering, researchers at the Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI have developed an innovative method for reclaiming high-quality continuous carbon fibers from composite materials using high-power lasers — a breakthrough that could significantly reduce industrial waste and production costs.
Carbon fiber composites, known for their exceptional strength-to-weight ratio, are widely used in aerospace, automotive, and energy industries. However, their complex structure — especially in thermosetting composites — has made recycling a long-standing challenge, often resulting in fiber degradation or downcycling. The new process, developed by the Fraunhofer EMI team, tackles this issue head-on by enabling the efficient recovery of intact, high-performance fibers.
The technique involves Innovative Recycling Method for Carbon Fiber a laser-induced localized pyrolysis process, in which high temperatures degrade the polymer matrix of fiber-reinforced plastic without damaging the embedded carbon fibers. This method is particularly promising for recycling pressurized hydrogen tanks, which contain continuous fiber windings around a plastic liner to withstand internal pressures of up to 700 bar.
“What makes this process special is that we perform the pyrolysis of the matrix and the unwinding of the fiber roving simultaneously, at a reasonable speed without damaging the carbon fibers,” said project manager Mathieu Imbert. The key lies in maintaining the optimal temperature window — between 300 and 600°C — to break down the matrix while preserving the integrity of the fibers.
According to researchers, the reclaimed fibers demonstrate mechanical properties equivalent to those of new materials. The process also boasts substantial economic and ecological advantages, consuming only about 20% of the energy required to produce virgin carbon fiber and drastically reducing processing time.
The project, part of the German Federal Ministry for Economic Affairs and Climate Action’s DigiTain initiative, will continue through the end of 2025. The Fraunhofer EMI team is actively working on further increasing energy efficiency and enhancing the quality of the recycled material.