The EU-funded MORPHO project has made significant strides in advancing sustainable recycling and disassembling techniques for Carbon Fiber Reinforced Polymers (CFRPs). These materials are widely used in aerospace and other high-performance industries, but their environmental impact remains a pressing concern due to challenges in recycling. The MORPHO project has introduced groundbreaking solutions, including the adaptation of a pyrolysis recycling technology, followed by an oxidation, and a laser shock disassembling technology, to address these challenges.
Pyrolysis consists in heating the CFRP in an inert atmosphere to decompose the organic resin without oxidation of the carbon fibres (CF). The decomposition of this composite material occurs in a temperature of 500°C so that the resin that binds the CF is decomposed. After pyrolysis, the fibres surface remains contaminated with a solid deposit and a subsequent post-pyrolysis treatment by oxidation using air at 500°C is mandatory to burn it, and so to clean the fibres surface, before re-combining the recovered carbon fibres (rCF) with plastic.
A Collaborative Innovation
The pyrolysis process, spearheaded by the COMET Group — an industry leader in metal waste management and recycling — represents a major technological leap. Initially developed for processing organic shredder residues generated by the recycling of metal waste, this technology has been adapted to recycle Polymer Composite Materials.
Following successful demonstration at lab scale, where rCF exhibiting mechanical properties comparable (-10%) to virgin carbon fibres were made, the work carried out to upscale it at semi-industrial level showed promising results, opening opportunities for industrial application. Further optimisation at industrial scale is expected to reproducibly make high quality rCF, viable for reuse in high-performance applications at large scale.
This development demonstrates the potential of pyrolysis as a scalable solution for recycling CFRPs, significantly reducing environmental impact and advancing circular manufacturing practices.
Quentin Van Haute, R&D Engineer at COMET, reflects on the success of the project:
“Over the course of the MORPHO project, we have consistently achieved high-quality fiber recovery through a pyrolysis followed by oxidation process. These results demonstrate the potential of this process to recycle and to reuse carbon fiber, and consequently to reduce environmental impact, at an industrial scale.”
Innovative Milestones Achieved
MORPHO’s multidisciplinary approach combines cutting-edge laser-shock disassembly with optimized pyrolysis processes. The project has achieved several key milestones:
- Efficient Fiber Recovery: A two-step pyrolysis and oxidation process was refined to ensure high-quality fiber recovery with minimal mechanical degradation (limited to just 10%), enabling scalability from lab to semi-industrial production.
- Laser Shock Disassembly Simulation: Numerical models were developed to virtually optimize and upscale the process from small test samples to full-scale composite panels, facilitating industrial adoption.
- Circular Manufacturing: The recovered carbon fibers demonstrated strong potential for reintegration into high-performance components, further reducing dependence on virgin materials and advancing sustainability objectives.
A Model for Green Innovation
The MORPHO project exemplifies how innovative thinking, and the adaptation of existing technologies can solve critical challenges in new industries. By focusing on sustainable composite recycling, MORPHO contributes to a greener, more circular economy.
As industries increasingly prioritize sustainability, MORPHO’s pioneering achievements pave the way for cost-effective recycling solutions that minimize environmental impact. This marks a significant step forward for the aerospace sector and beyond, demonstrating the critical role of EU-funded initiatives in driving progress toward a more sustainable future.
About the MORPHO Project
The MORPHO project is a HORIZON2020-funded initiative aimed at advancing manufacturing, repair, and recycling technologies for aerospace components. By integrating innovative sensor systems, disassembly methods, and recycling techniques, MORPHO seeks to enhance efficiency, performance, and sustainability in the aeronautical industry.
Led by the Ecole Nationale Supérieure d’Arts et Métiers (ENSAM), MORPHO brings together 10 partners from six countries: Arts et Métiers (France); Technische Universiteit Delft (Netherlands); University of Patras (Greece); Safran Tech (France); Fraunhofer IFAM (Germany); Synthesites (Greece); Comet Group (Belgium); FiSens (Germany); ESI Spain (Spain); Fundación Empresa Universidad Gallega – FEUGA (Spain).
The project began in April 2021 and concludes this January, marking the culmination of nearly three years of collaborative efforts to develop cutting-edge recycling and manufacturing technologies for a more sustainable aerospace industry.