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How is Recycled Carbon Fiber made?

Recycled Carbon Fiber as a sustainable material for hulls

Common Process:

The carbon composites are put in a furnace and are heated to approximately 400-600°C. This is done to burn off the epoxy resins in order to reclaim the raw fibers from the finished product. This heating process is the most common way of separating the Carbon Fiber from the resin.

New and Innovative Process:

  • FC Carbon obtains their RCF from high quality forms of Carbon Fiber that are separated from the resin using a cold system. This does not damage the mechanical properties of Carbon Fiber, as the common process does.
  • This new patented system is also much more reliable because it does not modify the length, quality and mechanical characteristics of the carbon fiber.
  • FC Carbon’s cold system technology is much more sustainable than the common hot system, due to the lack of fumes produced in this process.

By: Rayan Ferretti

Y11 Oasis

Similar Worldwide Project

There is a very big link between my personal project’s goal and World Sailing’s goal for improvement of international sailing. Both my project and the World Sailing Agenda are working to improve sustainability in sailing. They both focus on the of material waste in this sport and try to avoid the excessive remanufacture of materials used in sailing.

In Recommendation One of the World Sailing Agenda 2030 (Deliver Sustainability through Technical Standards), 3 out of 11 targets are applicable to my project. These three targets are:

  • Develop a reuse program for used equipment, benefiting emerging nations.
  • Require a 50% reduction in boat building waste (by weight).
  • Require that 90% of a boat (by weight) is recyclable for Olympic classes at the 2028 Games.

Besides the common goals between my project and the WSSA, I aim to raise awareness of unnecessary new productions but instead recycle from the existing fleet. To me, the sustainability should also be limiting the use of recycled carbon fiber in order to avoid over production of it.

With my goal, I am specifically concentrated on preventing the unnecessary production of brand new carbon fiber every time it is needed. I am also specifying my project on making hulls alone more sustainable instead of World Sailing’s aim, which is to “develop a reuse program for used equipment” and “ensure that 90% of a boat is recyclable”.

What makes Recycled Carbon Fiber unique?

Globalization and Sustainability

Similar Worldwide Project

Whatever we do in every day life as a human has an impact on our environment, economy and community. Environmental awareness should be embed in every one of us. The evidence of human impact on our environment is growing every day, increasing public awareness and concern about environmental issues.

  • Recycled Carbon Fiber has the same characteristics as carbon fiber, meaning that it is very robust, light and extremely durable. Carbon Fiber is already being used in hulls designed for competitive racing to make them as light and as fast as possible.
  • RCF is extremely sustainable because it uses reprocessed carbon fiber parts that are thrown away. The leftover parts could be parts of damaged carbon fiber hulls or dumped vehicle parts. Sustainability is evident here because of the wasted products being reused and broken down to recreate a new product.

World Sailing, the governing association for the international sport of sailing, has launched the “World Sailing’s Sustainability Agenda 2030” in November of 2017. They are seeking for feedback from stakeholders, sustainability professionals, and especially sailors, from all around the world.

One of this project’s targets includes “developing a reuse program for used equipment, benefiting sailors in emergent nations”. This target alone can show how World Sailing’s aim for the future is to be as environmentally friendly and sustainable as possible.

Since they were looking for feedback from sailors around the world, I wanted to support this ‘Sustainability Agenda’ so I filled out a feedback form that will help them specify their targets more on certain areas of sailing. I did so because I wanted to try to involve the U.A.E in this project as well. World Sailing’s project does not currently involve the U.A.E, so the link between my personal project and their project promotes their set targets here in the U.A.E.

How can I act to minimize my impact on the natural environment?

Having learnt to care for the environment around me, I wanted to see how I could possibly contribute to increasing sustainability in my area of interest. So I was curious to learn about how sailboats could be reused instead of thrown away.

When I am not in school I spend most of my time at DOSC (Dubai Offshore Sailing Club), and, being a sailor, I comply to the rules and regulations set, relevant to all training centers worldwide: pollution control, waste management, energy and water use and wildlife conservation.

  • No down cycling is present in the process of recycling carbon fiber because if the carbon fiber parts from hulls are reused to create even more hulls, it is defined as recycling. Recycling is the process of taking waste materials and converting them into new materials or products.
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