Energy Efficiency in Carbon Fiber Production

A new technology using microwaves and plasma heating to produce carbon fibers in an energy-efficient manner, can be used to create highstrength composite materials more cheaply and efficiently. The German Institutes of Textile and Fiber Research (DITF) are part of the Carbowave research consortium, which aims to improve and commercialize microwave and plasma-induced carbonization.

The combination of high strength and low weight makes carbon fibers almost indispensable in manufacturing modern lightweight products. Major industries, such as automotive, aerospace, and renewable energy, are increasingly relying on high-strength carbon fiber composites.

Despite their advantages, these materials are complex and energyintensive to produce. Stabilization and carbonization of the fibers, which are often made from petroleum-based polyacrylonitrile (PAN), requires slow process control in high-temperature furnaces. Despite the considerable energy input, a low material yield is achieved due to the long dwell time in the ovens.

A new process uses microwave and plasma heating to replace the traditional stabilization and carbonization process with energy-saving technology. With this technology, energy is only induced into the fibers locally, thereby minimizing energy loss. This process shortens the production time of carbon fibers, enabling higher production volumes with lower energy consumption.

A European research consortium has joined forces under the name “Carbowave” to optimize and market the process. Their specific research objectives are to develop an optimal coating for PAN fibers that improve microwave adsorption, to develop a plasma heating system for the oxidative stabilization of PAN fibers, and to advance microwave and plasma technology for continuous processes.

DITF is responsible for implementing these processes in continuous production and on pilot lines in a pilot plant. In the joint project, the central task of DITF is the stabilization of the precursor fibers with plasma technology. This involves combining plasma and low-pressure technology to reduce energy consumption in the stabilization process.

In terms of the circular economy, the Carbowave project includes recycling of carbon fibers. The new process technologies will allow for the microwave-assisted decomposition of carbon fiber composites (CFRP). www.ditf.de

Fashion with World’s First Bioinspired Structural Color Technology

Patrick McDowell, the renowned British brand at the forefront of sustainable luxury fashion, announced a new collaboration with Sparxell, the world-first, nature-inspired color platform technology company founded by University of Cambridge scientists Dr. Benjamin Droguet and Professor Silvia Vignolini. The company creates high-performance, biodegradable colorants that are free from plastic and toxic chemicals using plant-based cellulose. This collaboration will unveil a couture printed gown and a commercially available shirt dress, marking a defining moment as Patrick McDowell becomes the first brand to integrate Sparxell’s cuttingedge innovations into fashion.

McDowell continues to reinforce his brand’s commitment to a more responsible fashion industry. This collaboration showcases the potential for innovation to redefine luxury, with the collection making its debut at Future Fabrics Expo 2025, the world’s leading platform for sustainable materials for the fashion industry. The launch signals a broader industry shift toward forward-thinking practices that will shape the future of luxury as well as mainstream fashion. www.sparxell.com

Carbon-Fiber Recycling Innovation Wins Funding

Uplift360, a cleantech company, has been awarded an Innovate UK Smart Grant to scale its pioneering low-energy chemical recycling technology, ChemR. Selected as one of only 44 successful projects from a pool of 2,134 applications, ChemR is the world’s first ambientcondition chemical recycling process for advanced composite materials. It has the potential to transform carbon fiber waste management across all sectors.

Carbon Fibre Reinforced Polymers (CFRPs) are rapidly expanding due to their high strength, low weight, and corrosion resistance. Yet, as much as 50% of CFRP is wasted during manufacturing, and the UK currently produces between 30,000-50,000 tonnes of CFRP waste annually – with a potential value exceeding £1.2 billion if effectively recycled. With only 20% of CFRP waste being recycled – and less than 2% reused due to limitations in thermal and mechanical recycling methods – the sector urgently needs a scalable, sustainable alternative. www.uplift360.tech