Boeing interest in new carbon fibre recycling process

Carbon fibre's strong, lightweight properties have proved invaluable in the manufacturing of bodywork for aircraft, but make the material difficult to recycle.

Milled Carbon is a member of the Aircraft Fleet Recycling Association, which has been tasked by Boeing to look into ways to recycle old aircraft

Milled Carbon Ltd, based at Wootton Wawen, near Henley-in-Arden, has developed a pyrolysis process that it says can break down the material to produce a usable product that can replace virgin carbon fibre.

Although the recycled carbon fibre does not have the stringent physical properties of its virgin equivalent, the company believes there are potential uses for it – as well as market demand.

John Davidson, managing director of Milled Carbon Ltd, said: “We're getting a lot of enquiries from companies that want to use the recyclate for applications where its strength, weight, durability and electrical properties are of interest. We're also developing forms of the recycled fibres where, traditionally, virgin carbon fibres have always been used.”

The Milled Carbon process can be used to treat both “cured” carbon fibre – material that has been thermally set – and “uncured” material, and as well as used carbon fibre, the company says it can recycle off-cuts from manufacturers.

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The company said it is working with several composites manufacturers which are interested in disposal and recycling of this previously problematic material, and that there is a “healthy market” for its recyclate. There is good demand particularly among injection moulders and for use in non-woven materials, it said.

As well as working with various universities to improve its process, Milled Carbon has also been working with the Aircraft Fleet Recycling Association on a recycling programme recently brokered by Boeing to considered new approaches to the disposal of aircraft.

Bill Carberry, aircraft and composite recycling project manager at Boeing, said: “Recycling is good for the environment and good for business. Boeing supports efforts like this one that will foster environmentally sound practices. This new carbon fibre recovery technology is a great step forward.”