Experimental feasibility and environmental impacts of compression molded discontinuous carbon fiber composites with opportunities for circular economy

Compression molding of carbon fiber sheet compounds (CF-SMC) is a promising technology to reduce the waste composites and drive sustainable development in lightweight applications. Both, production prepreg scrap end-of-life components can be used efficiently recycling process with an apparent sandwich structure virgin recycled materials. This contribution investigates on example structural automotive component (transmission crossmember). A one-shot compression was developed which enables cost-efficient, large-scale manufacturing cycle times about two minutes. The process–structure–property–performance relationship experimentally characterized studies prototype tests. multilayered hybrid materials maintains manufacturability mechanical performance compared primary CF-SMC. environmental impacts were assessed within comparative life assessment (LCA). Different material scenarios analyzed for produced. It revealed lower than industrially reference version aluminum most impact categories. combination reveals opportunities circularity multistage use industrial recyclates varying quality requirements