reFrame - Recycled Fiber Reinforcements for Advanced Manufacturing and Engineering

The use of fiber-reinforced plastics in mobility applications offers the potential to reduce fuel consumption and CO2 emissions. Nevertheless, their increasing use poses a major challenge in the long term, as the recycling of these energy- and cost-intensive structures at the end of their life cycle is considered critical. Existing recycling approaches for fiber composite structures (chemical, pyrolytic, mechanical) often lead to a deterioration in mechanical properties compared to virgin materials. This makes it difficult to use recycled materials in highly stressed, weight-sensitive applications, such as those found in aviation. The current state of industrial and scientific knowledge in the handling of recycled materials, especially with regard to their consideration in structural design and damage modeling, must therefore be considered insufficient.

Objectives

The aim of the reFrame project is to develop a closed recycling routine for thermoplastic fiber composites. This involves the functionalization of production-related prepreg scraps and end-of-use components in a recycling process and their subsequent processing into a thermoplastic, short fiber-reinforced compound. By combining this recyclate with continuous fiber-reinforced carbon fiber tapes, new high-performance applications are to be developed. The tapes are bonded either using thermoplastic automated fiber placement (TAFP) or in a hot press process. The material concepts developed are then tested and evaluated in the structural design of an electrically powered aircraft.

Benefits

The project aims to increase the sustainability of fiber-reinforced plastics in future mobility applications through targeted research into a closed recycling loop.

Approach

The IFW is researching the use of recycled and bio-based materials in thermoplastic automated fiber placement. Its research activities also include the use of AI-based process monitoring and digitization approaches, as well as the identification of energy-efficient laying strategies. Meanwhile, Clausthal University of Technology is analyzing the material aspect of recycling thermoplastic fiber composites and the production of core materials. Braunschweig University of Technology is researching the use of recycled materials in aircraft structures, design methods adapted to the materials, and reversible joining methods.

Are you also interested in a cooperation project?

Contact Nick Knupfer via email at knupfer@ifw.uni.hannover.de or by phone at +49 4141 77638-202.