A direct process to reuse dry fiber production waste for recycled carbon fiber bulk molding compounds

Recycling concepts for composites are gaining importance facing constantly growing production rates in multiple sectors. Today, a high percentage of the carbon fiber waste is generated during production. The unimpregnated share of waste cannot be reused as high-performance non-crimp fabrics, since shape, size and orientation of the patches were changed during the previous production step. The approach presented here shows the direct processing of chopped dry non-crimp fabrics cutting waste to Bulk Molding Compounds. The manufactured BMC materials are able to compete with materials from state-of-the-art Sheet Molding Compounds produced using virgin carbon fibers in terms of mechanical performance.