Validation of Industrially Recycled Carbon-Fibers Upcycling: Reuse of ReCF in a Component as Proof-of-Concept of Circular Economy

Carbon-fiber-reinforced polymers (CFRPs) are excellent candidates for lightweighting vehicle components. However, the lack and the cost of raw materials prevent their widespread application. Moreover, CFRPs are difficult to recycle. A recently started-up carbon fiber recycling plant (FIB3R, designed by HERAmbiente @Imola—BO—Italy, from a joint UniBo and Curti Costruzioni Meccaniche patent) produces now up to 320 tons per year of ReCF. Tailoring and optimizing the specific recycling process to boost the final ReCF properties, as well as the re-impregnation strategies to optimize composites production, are at the basis of a successful result. The use of greener alternatives is still far from being a diffused practice in the mobility industry. This is mainly due to the lack of specifically suited industrial processing methods, material knowledge, and design tools. Thus, it requires the common effort of sustainable materials experts, green manufacturing technologists, and a circular economy approach to support this transition step, the widespread use of ReCF within the CFRP value chain.