The partners of the Terra Preta project have demonstrated that material offcuts from the production of composite aircraft components can be used to manufacture other less critical parts through the recycling process developed by Cetim.
What if we could use offcuts from the production of aircraft access panels and fuel tank access panels to make other parts, thereby reducing the carbon footprint from the manufacture of these parts and saving on the quantity of virgin material used? As part of a partnership study led by Sogeclair Equipment, coordinated by Safran Seats and financed by the French Civil Aviation Authority (DGAC), Cetim assessed the potential of its Thermosaïc thermoplastic composite recycling process. As it turns out, this solution provides an economical alternative to virgin materials, thereby significantly reducing the carbon footprint, by using more than 40% of the waste, in a closed circuit, on the same program. Ultimately, this process saves 70% of the material used in the manufacture of the initial part and the recycled part.
An improved recycling process
Currently, aircraft are increasingly being made of composite materials. However, there are challenges to be addressed when it comes to recycling these composite materials throughout their lifecycle, from aircraft production through to decommissioning. In this respect, Cetim has developed the Thermosaïc recycling technology, which won a prize at the JEC Awards in 2018.
An improved version of the process was recently implemented including for the thermomechanical recycling of high performance composite materials such as carbon fibres and high temperature polymers (> 100°C). This process was used as part of the Terra Preta project for the industrial application of new underwing technical access panels, currently being developed by Sogeclair Equipment. A demonstrator of this solution was showcased at JEC 2024.
Working alongside its partners, Cetim defined the appropriate recycling process, using its grinding equipment and the Thermosaïc line to recreate composite sheets from production offcuts and scraps. These sheets will then be used as raw materials to manufacture new parts.
This process has been optimised in conjunction with Sogeclair to process waste from the production of aircraft fuel tank access panels made of carbon-PPS composites and to redirect the recycled materials towards other applications. “The recycled materials can be used to produce technical access panels for electrical and hydraulic equipment, in areas where the mechanical stresses are less severe. While qualification tests are still ongoing, steps have been taken to prepare the ground for the future recycling of composite materials in the aerospace industry”, disclosed Christophe Cornu, from Cetim. This experiment could pave the way for other applications of parts manufactured from recycled material offcuts, with significant impact in terms of industrial decarbonisation.