Researchers at the University of Southern California (USC) have developed an innovative recycling method for carbon fibre composites—a breakthrough that could greatly benefit industries like construction, automotive, and aerospace, where lightweight and durable materials are in high demand.

Carbon fibre composites are valued for their strength and low weight, making them ideal for applications requiring strong yet lightweight structures. However, they are challenging to recycle effectively, as conventional recycling methods degrade the material’s structural integrity. This new approach preserves the properties of carbon fibres, allowing them to be reused in high-performance applications without significant quality loss, making it an important step forward for sustainable material reuse.

How the New Recycling Process Works
This method, created in collaboration with industry experts, involves breaking down the resin that bonds carbon fibres in composite materials. The fibres can then be separated and reused, retaining their original strength and durability. Traditional recycling methods tend to damage or reduce the quality of these fibres, but the USC method avoids this by targeting only the resin, leaving the fibres intact. This innovative approach has potential applications across various fields where carbon composites are used.

Fungal Enzymes Aid in the Recycling Process
A key element of this recycling breakthrough is the use of fungal enzymes to degrade the resins binding carbon fibres, making it easier to separate the materials. Researchers discovered that enzymes from certain fungi, such as Aspergillus niger, efficiently break down the resin without harming the fibres, making them reusable for new applications. This technique could inspire similar recycling approaches using natural catalysts, supporting a biobased and circular design approach.

A Potential Boost for Sustainable Design
For architects, interior designers, and automotive designers, this recycling method offers a sustainable alternative to conventional carbon fibre production. In the architecture and interior design sectors, these reclaimed carbon fibres could be repurposed into structural components or design elements, reducing the need for virgin materials and the environmental impact of new production. The automotive industry can also benefit from recycled carbon fibres for vehicle parts, supporting the shift towards lighter, more fuel-efficient, and environmentally friendly cars.

Circular and Biobased Potential
The biocatalytic recycling process opens up opportunities for biobased products, adding value to the circular economy. For example, reclaimed carbon fibres could find new life in eco-friendly products or be reformed into high-quality components for future designs. This aligns well with growing demands for sustainable and circular materials in architecture, interior, and product design.

This innovative recycling method shows promise for enabling designers and manufacturers to adopt more sustainable materials without sacrificing quality. It could become a model for recycling other composite materials, contributing to a reduction in carbon emissions and waste in manufacturing-intensive industries.

Source: University of Southern California
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