Re-Cell Develops Recycled Carbon Fiber Structural Batteries for Aviation

Updated on August 05, 2026 • 4 min read

The Re-Cell project is developing structural batteries and supercapacitors made from recycled carbon fiber, aiming to reduce aircraft weight by combining energy storage and structural functions within a single composite component.

Coordinated by Spanish aerostructures manufacturer Sofitec, the project brings together Aimplas, the Spanish Plastics Technology Centre, and I2CON to develop multifunctional composite materials for future aircraft.

Rather than using separate batteries and structural components, Re-Cell seeks to integrate both functions into lightweight composite structures, supporting the aviation industry’s long-term electrification and sustainability goals.

Structural Components That Store Energy

Aircraft electrification remains one of aviation’s biggest engineering challenges.

While batteries enable electric propulsion and onboard electrical systems, they also add significant weight, reducing overall efficiency.

The Re-Cell project addresses this issue by developing composite materials capable of serving two purposes simultaneously:

• Structural load-bearing
• Electrical energy storage

According to Sofitec, these multifunctional materials could help reduce overall aircraft weight by eliminating dedicated energy storage components in certain applications.

Initially, the technology is intended for non-critical aircraft systems, including cabin lighting, before being evaluated for broader aerospace applications.

Recycled Carbon Fiber Supports Circular Manufacturing

One of the project’s distinguishing features is its use of recycled carbon fiber.

Rather than relying entirely on virgin reinforcement materials, researchers are developing recycling and material treatment processes that allow recovered carbon fibers to be incorporated into advanced energy-storage composites.

The approach supports circular manufacturing while reducing composite waste generated across aerospace and other carbon fiber-intensive industries.

Researchers are also investigating methods to integrate recycled fibers into polymer matrix systems capable of delivering both mechanical strength and electrochemical performance.

Research Focuses on Multiple Technical Challenges

Beyond material recycling, the project addresses several scientific challenges associated with structural batteries.

These include:

• Functional solid electrolyte development
• Recycled fiber consistency
• Mechanical and electrochemical performance integration
• Composite processing methods

Successfully balancing structural performance with energy storage remains one of the primary engineering barriers to commercial structural battery technologies.

Full-Scale Aircraft Demonstrator Planned

The next phase of Re-Cell will include manufacturing and testing a full-scale demonstrator integrated into an aircraft landing gear component.

Researchers will evaluate:

• Structural performance
• Energy storage capability
• Manufacturing processes
• Integration into aerospace production environments

The demonstrator is intended to validate both the composite material and its suitability for industrial aerospace manufacturing.

Multifunctional Composites Continue to Evolve

Professor’s Analysis

For decades, composite materials have primarily been designed to perform one role: carrying mechanical loads while reducing structural weight.

Projects such as Re-Cell represent a broader shift toward multifunctional composites, where structural materials perform additional tasks beyond supporting the airframe.

Around the world, researchers are exploring composites that can:

• Store electrical energy
• Monitor structural health through embedded sensors
• Provide thermal management
• Enable self-healing after damage

Structural batteries are among the most technically demanding of these concepts because they must satisfy both mechanical certification requirements and electrochemical performance targets.

Using recycled carbon fiber adds another layer of complexity, as recycled fibers often exhibit greater variability than virgin materials.

Although commercial aircraft are unlikely to rely on structural batteries for primary energy storage in the near future, successful demonstration in secondary systems could open the door to wider adoption as material technologies continue to mature.

Supporting More Sustainable Aircraft Design

The Re-Cell project highlights how recycled composite materials may contribute to future aircraft development beyond traditional lightweight structures.

By combining energy storage, structural performance and carbon fiber recycling within a single material system, the project supports ongoing efforts to improve aircraft efficiency while advancing circular manufacturing practices.

If successfully industrialized, multifunctional recycled composite materials could become an important area of innovation as aerospace manufacturers continue developing lighter and more sustainable aircraft.

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