CAMX Award | Bidirectional Fabric Made of Recycled Carbon Fiber and Thermoplastic Filaments

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Originally Aired - Tuesday, October 18 8:30 AM - 10:00 AM

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Event Location

Location: CAMX Awards Pavilion


Event Information

Title: CAMX Award | Bidirectional Fabric Made of Recycled Carbon Fiber and Thermoplastic Filaments

Description:

Unsurpassed Innovation Award 

Company: Blackfabric

Description: The CAMX Award winners will be announced during Tuesday's General Session and will present in the theater at 12 pm. All entries will be on display throughout the week in the CAMX Awards Pavilion in the exhibit hallThanks to the knowledge in weaving technologies and subsequent processes, Blackfabric is able to take a step forward in sustainable solutions, developing the first high drapability fabric made with recycled carbon fibers. Discontinuous carbon fibers from recycling processes are oriented together with thermoplastic fibers in a commingled yarn, which incorporates the right percentage of matrix, obtaining a thermoplastic prepreg ready to be directly consolidated without need of additional processes.  However, it has been necessary to adapt the machinery of the weaving process, designing a special space protected from fibrils and dust, and adapting the production process to the yarn properties. The resultant bidirectional fabric is apparently similar to a conventional “wool fabric”, very flexible and moldable that adapts well to any geometry. It is easy to cut, manipulate and mold. It can be formed easily, with conventional thermoforming or stamping processes, avoiding additional impregnation processes, neither infusion nor injection, reducing processing times and notably reducing production costs. In addition, it maintains all the advantages of thermoplastic matrices; easy to store and transport, without expiration date, reducing leftovers, with short time processes, repairable and recyclable.  The alignment and orientation of the fibers tegether with the weaving pattern significantly improve the structural and mechanical properties of the composite. Blackfabric's recycled carbon fiber fabric has mechanical properties below the average results of virgin carbon fiber thermoplastic composites, but is up to 2 times better than the mechanical results obtained with non-oriented recycled fibers. This thermoplastic prepreg made with recycled fibers, can be used in many sectors and all those applications where high mechanical strength properties are not required. Like decorative elements, aesthetic parts, body interiors, home accessories, as well as for more functional applications in the world of sports goods and automotive parts, where you can opt for a more sustainable solution. 

Collaboration and Partnerships: Blackfabric, wich legal entitie name is Texfire Textils Tecnics SL, has develop the fabric construction development. Using the knowledge on weaving technologies, to develop and design a bidirectional fabric 0º / 90º using hybrid yarns, which combine recycled carbon fibers with thermoplastic fibers. Achieving a resulting fabric with recycled carbon fibers oriented in two directions, improving significantly the structural and mechanical properties of the compound, compared to currently known nonwovens and forged carbon solutions, which are made with recycled fibers placed in all directions randomly, in no order.  All the development and adaptation of the machines and technologies of weaving for this type of fibers has also been carried out.  We have received financial support from the European Galactica Calls, for the Pioneer Boucher Project, endowed with € 20,000 which has helped us to scale the pilot scale project on an industrial scale.   Blackfabric, wich legal entitie name is Texfire Textils Tecnics SL, has develop the fabric construction development. Using the knowledge on weaving technologies, to develop and design a bidirectional fabric 0º / 90º using hybrid yarns, which combine recycled carbon fibers with thermoplastic fibers. Achieving a resulting fabric with recycled carbon fibers oriented in two directions, improving significantly the structural and mechanical properties of the compound, compared to currently known nonwovens and forged carbon solutions, which are made with recycled fibers placed in all directions randomly, in no order.  All the development and adaptation of the machines and technologies of weaving for this type of fibers has also been carried out.  We have received financial support from the European Galactica Calls, for the Pioneer Boucher Project, endowed with € 20,000 which has helped us to scale the pilot scale project on an industrial scale.        

Concept and Design: The impressive growth in carbon fiber consumption in recent years is leading to a significant increase in leftovers and waste being dumped in landfills. As a result of all these needs, the Blackfabric project emerged to provide more sustainable, recyclable and high value-added solutions in the world of fiber-reinforced materials. Finding a new commercial use for recycled carbon fibers Blackfabric contributes to a common good. Upcycling current waste into a new product, revaluing it and re-entering it within the value chain, fostering the circular economy and enhancing recycling. The fact of being able to give more added value to recycled carbon fibers, thanks to mechanically and aesthetically improvements, making the material usable in multiple applications on the market, can clearly reduce the consumption of raw materials.  It is difficult to quantify the environmental impact at this early stage of the project, but it is clear that the use of recycled fibers significantly reduces the environmental impact.  It has been studied that the process of obtaining recycled fibers can reduce the global warming potential by up to 75%, and the amount of energy needed for its production is reduced by 60% compared to the production of virgin carbon fiber, which considerably reduces the carbon footprint of the final product.  In addition, the introduction of recycled carbon fibers into the value chain means that the use of virgin raw materials is reduced exponentially, consequently reducing the waste generated, closing the loop. Exponentially decreasing the manufacture of virgin materials, thus reducing the use of raw materials, and replacing them for recycled materials. All this entails a very important energy and CO2 saving, at the same time as you are adding value to the waste, turning it into a raw material for new products that enter the value chain.

Additional Information:  1- Bidirectional thermoplastic prepreg made with 100% recycled carbon fibers and thermoplastic polymers. 2- Discontinuous recycled fibers oriented at 0/90º with improved mechanical results 3- Thermoplastic prepreg ready to be directly thermoformed with no additional process 4- Aesthetic bidirectional fabric, with taffeta pattern, made with recycled carbon fibers.

Type: CAMX Awards


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