Recycled & Upcycled Thermoplastic Composites

Summary
Date	2022-?
Keywords	composites, recycling, upcycling, PEEK, PEKK, 3d-printing, sustainability, carbon fiber

High-performance thermoplastic composites — particularly carbon fiber reinforced PEEK and PEKK — are increasingly used in aerospace applications due to their excellent mechanical properties and processability. However, manufacturing scrap and end-of-life parts represent a significant waste stream that currently lacks viable recycling pathways.

This project explores upcycling strategies for CF/PEEK and CF/PEKK prepreg waste, converting offcuts and rejected parts into feedstock for large-format Fused Granule Fabrication (FGF) and other additive manufacturing processes. The goal is to demonstrate a closed-loop manufacturing model where aerospace composite waste is transformed into high-value printed structural components.

Recent work (2025) has demonstrated the feasibility of producing functional printed parts from upcycled CF/PEKK scrap, with mechanical properties competitive with virgin feedstocks for non-primary structure applications. This research contributes to the broader sustainability agenda in aerospace manufacturing.