LOCO 3

Low-CO2 Composite Components

Summary

Over the years, the TPAC has built an extensive project portfolio focused on advancing the recycling of thermoplastic composites. One standout initiative within this portfolio is the RAAK PRO project titled ‘TPC-Cycle’. In this project, two PhD students developed an innovative recycling process (Figure 1) that targets post-production thermoplastic composite waste from high-end industries. This waste is collected, shredded, and mixed into a compression moulding dough. The resulting dough contains centimetre-long fibres, which help retain much of the original reinforcing value of the composite material. Through the TPC-Cycle process, this dough is then used as input for compression moulding, enabling the creation of new parts from material that would otherwise have been disposed of.

In the years after, various projects at the TPAC have built towards the industrialisation of the process, with the ultimate goal of the process route being commercially viable and sufficiently mature for industrial adoption. LOCO3 contributes to this endeavour by demonstration of the recycling route for automotive industry. Together with project partners BaX Composites and SpiralRTC, the recyclability of carbon-nylon waste will be investigated. The aim is to establish a manufacturing chain in which plate-based half-fabricates, made from recycled thermoplastic composites, serve as input for an automated production line, enabling high-rate and high-volume manufacturing of automotive components. TPAC’s role involves demonstrating the processing chain and conducting a study on the relationship between material input, processing parameters, and part performance. Additionally, the life cycle and environmental footprint of parts produced using this strategy will be assessed.

Project partners

Spiral RTC, BaX Composites

Duration

The project runs from the start of January 2025 to the end of December 2027.

Funding

LOCO3 has been awarded under the Eureka Network Eurostars 3 – Call 6 frame programme (Eurostars No: 5826; Tübitak No: 9249509)