CFRP Recycling

Contents

Introduction
FRP: The Representative Image of Composites
Disadvantages of CFRP
Recycling CFRP
Summary

Introduction

These days, technical jargon such as FRP, CFRP, composites, and weight-efficiency often appear in the media for a range of applications. Such terms may be annexed with “lightweight, strong, and non-corrosive” materials that substitute metals. But what exactly are these materials?

FRP: The Representative Image of Composites

Fiber Reinforced Plastic (FRP) is a plastic polymer composited with fibers to enhance its strength. As suggested by the name, Glass Fiber Reinforced Plastic (GFRP) is a plastic polymer and type of FRP that employs glass fibers as the reinforcing material.

The initial letter refers to the type of fiber used; C being carbon, G being glass fibers, and A being aramid fibers. Since CFRPs are composed from a combination of reinforcing fibers and resin (plastic), they are referred to as a “composite” or “composite material”.

In this issue, we will discuss recycling of Carbon Fiber Reinforced Plastics.

Disadvantages of CFRP

Although CFRP has gained considerable attention across industries for its lightweight and strong properties, every rose has its thorn. In addition to the high costs of raw materials and CFRP, the fiber reinforced plastics, such as CFRP, are anisotropic materials that exhibit varying strengths according to the orientation of the fibers. This “custom-design” element can lead to an unfavorable material yield rate at the time of manufacturing due to waste from discarded unused prepregs which expire after six months, even when stored frozen. Expensive and complex manufacturing processes, difficulties in mass production, and poor recyclability of materials are remaining issues in CFRP productization.

Recycling CFRP

Let’s take a look at waste materials collected during CFRP recycling. The diagram below illustrates the workflow of the key manufacturing method used in CFRP fabrication—autoclaving.

Each process in the workflow generates uncured pre-molding waste and molded scrap material.

The major stumbling block, however, is the inability to collect these wastes homogenously because the type of resin and fiber employed will differ depending on the product, structure, and application. Another major hurdle is the difficulty in separating CFRP waste from other substituents. uring pre-curing, illustrated on the diagram left, waste from protective film and backing paper used to protect materials are disposed of together with CFRP waste. Moreover, as many cured CFRP composites contain GFRP and AFRP to enhance CFRP performance, or additional structural metal inserts, it is often difficult to collect only the CFRP from cured waste.　This inability to collect CFRP in isolation greatly hinders its recyclability.

Summary

This issue discusses recycling of CFRP. In Japan, increasing numbers of companies are seeking to commercialize their business with recycled carbon fiber (CF). At Uchida we are working with such manufacturers and exploring potential ways to better utilize waste material and recycle CFRP. Waste shouldn’t be regarded as an inevitable outcome but as an issue that can be resolved. At Uchida, we are focusing on solutions to reduce waste and leverage it for other means from within our immediate surroundings.

ABOUT UCHIDA - 55 years since our founding

We leverage a wealth of technical expertise as a CFRP molding and processing manufacturer using FRP, GFRP, and CFRP materials. We offer a one-stop solution, encompassing design, analysis, manufacturing, secondary processing, assembly, painting, quality assurance, and testing.

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UCHIDA's equipment

We have cutting-edge equipment to ensure that we can address even the most advanced challenges of our customers.

DMG森精機 - VS1000/40/2050
X軸：2,050mm（ストローク）／ Y軸：1,000mm ／ Z軸：600mm ／テーブル作業面：2,250×1,000mm

ASHIDA MFG Co., Ltd.
Autoclave Oven 2
Size : Ø1,150x1,000mm / Operating temperature : at normal temperature - 400℃ / Design pressure : 2.0Mpa (maximum working pressure) / Vacuum system : back suction system / Vacuum units : 5

ASHIDA MFG Co., Ltd.
Autoclave Oven 3
Size : Ø3,000x6,000mm / Operating temperature : at normal temperature - 200℃ / Distribution accuracy : ±2.5℃less / Heating rate : 4.0℃/min. (empty furnace) / Cooling rate : 4.0℃/min. (empty furnace) / Design pressure : 0.99Mpa (maximum working pressure) / Working pressure : 0.7Mpa less (if no specification from the manufacuturer 0.3Mpa around) / Pressure accuracy : ±0.02Mpa（for pressure setting of ０ - 0.99Mpa/cm²） / Boost pressure accuracy : 0 - 0.03Mpa/min / Pressure source : compressed air (regular use) / Vacuum system : back suction system / Vacuum units : 10

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Oven
Size : W1,000xH1,000xD1,000mm / Temperature range : Environmental Temperature +20 - 300℃ / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 45min less / Vacuum system : back suction system / Vacuum units : 10

ESPEC CORP.
Temperature & Humidity Chamber

INSTRON
Static Universal Testing Machine 5985

Oven
Size : W7,000xH3,000xD2,000mm / Temperature range : Environmental Temperature +20 - 300℃ (Max) / Temperature elevation capability : Environmental Temperature (20 - 40℃) - 300℃ / 60min less / Vacuum system : back suction system / Vacuum units : 10

NEO
X axis : 4,000mm (stroke) / Y axis : 2,000mm / Z axis : 1,200mm / C axis : 0° - ±270° / B axis : 0° - ±110° / Table working place : 4,000x2,000mm

【開発】
3Dプリンター | Markforged

Painting booth
Various painting, and clear finish is done in dedicated painting booth

Adhesion, Finishing, Coating Room
Finishing process, such as trimming, drilling, and bonding, surface treatment of the molded product type and is done in a private booth

Toshiba Matrixeye EX (Ultrasonic flaw detector)
Matrix-Arrey : 32

AMETEK CREAFORM Metra
SCAN750 Elite (3D scan)

Olympus Corp.
Inverted Microscopes

Oven
Size : W450xH450xD450mm / Temperature range : Environmental Temperature +20 - 650℃ / Temperature elevation capability : Environmental Temperature+50 - 650℃/120min less

Cutting Plotter Table working place : W1,500xL3,500mm

SHIMA SEIKI MFG., LTD
Cutting Plotter

KUKA
Robot

Krauss Maffei
Epoxy resin injection machine Resin 60L ／ Hardener 25L

Krauss Maffei
630t Press machine Height total 5,200mm ／ Length max 1,500mm ／ Width max 1,200mm ／ Whole cycle time per component part 240sec

DMG森精機 - NV5000B/40
X軸：1,020mm（ストローク）／ Y軸：510mm ／ Z軸：510mm ／テーブル作業面：1,320×600mm

Big sized clean room
JIS B 9920 cleanliness class maximum concentration (Pcs/m³） / Class 5 : 100,000m³ / Capacity : m² (16,000x16,000mm) 760m² (16,000x16,000x3,000mm) / Temperature and humidity condition : Temperature : 23℃±3℃, Humidity 65% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Ambient conditions : Temperature 35℃ during summer, Humidity 70% less / Temperature -5℃ during winter, Humidity 40% less