Published: March 2026
Estimated reading time: 4 minutes
From Scrap to Structural Component
In composite manufacturing, recycling has often been discussed—but rarely implemented at a structural level.
That gap is beginning to close.
Epsilon Composite and Nova Carbon have jointly developed pultruded carbon fiber machine beams containing more than 30% recycled carbon fibers (rCF), sourced directly from production scrap.
This is not a laboratory concept.
The beams have been:
- manufactured
- machined to tight tolerances
- prepared for integration into industrial machinery
The shift here is clear: recycled carbon fiber is moving from experimental use into load-bearing applications.
A Short-Loop Model: Recycling Within the Production Ecosystem
The collaboration is built around a localized circular model.
The process flow is direct:
- Carbon fiber scrap generated during Epsilon’s production
- Collected and processed by Nova Carbon
- Reintegrated into Epsilon’s pultrusion line
Both companies operate near Bordeaux, enabling:
- reduced transport requirements
- faster material turnaround
- tighter process control
From a manufacturing standpoint:
This is not just recycling—it is process integration.
Why Pultrusion Is the Right Entry Point for Recycled Fibers
Pultrusion is inherently suited for:
- continuous production
- aligned fiber reinforcement
- consistent cross-sectional profiles
These characteristics make it more tolerant of recycled fibers compared to:
- complex layup processes
- high-performance aerospace laminates
In this case, recycled fibers are incorporated into:
- machine beams
- structural profiles requiring dimensional stability
The final parts are then:
- assembled with metal interfaces
- precision machined to meet industrial tolerances
Structural Application: Moving Beyond Secondary Use
Historically, recycled carbon fiber has been limited to:
- non-structural components
- fillers or low-load applications
This project represents a different step.
According to the partners, it is:
the first industrial structural application of pultrusion integrating a significant proportion of recycled carbon fiber.
That distinction matters.
Because structural use requires:
- predictable mechanical performance
- process consistency
- quality validation
From Demonstrator to Industrial Adoption
The project was first introduced as a proof-of-concept profile at JEC World 2025.
Since then, it has progressed to:
- industrial-scale production
- qualification for a client application
- readiness for commercialization
The timeline is notable.
Moving from concept to qualified part in this timeframe indicates that the technology is not experimental—it is production-ready.
Environmental Impact: Quantifying the Benefit
The collaboration has already processed more than:
- 1.8 tonnes of carbon fiber scrap
Measured environmental benefits include:
- 29 tonnes of CO₂ emissions avoided
- 330,000 MJ of fossil energy saved
- over 4,600 m³ of water preserved
These figures are based on assessments aligned with ISO 14069, comparing recycled material use against virgin carbon fiber production.
From an industrial perspective:
The value is not just environmental—it is measurable and standardized.
Manufacturing Perspective: What This Changes
For composite manufacturers, the implications are practical.
1. Scrap Becomes a Resource
- internal waste streams can be reintegrated
- material efficiency improves
2. Cost Structure Potentially Improves
- reduced reliance on virgin carbon fiber
- lower raw material costs over time
3. Supply Chain Shortens
- local recycling reduces external dependency
4. Sustainability Becomes Embedded
- not added as a secondary process
- integrated into production flow
The Role of Collaboration in Industrial Scaling
This project highlights a recurring pattern in advanced materials:
- established manufacturer → production capacity and market access
- specialized recycler → material innovation and processing expertise
Together, they create:
- faster development cycles
- practical industrial solutions
Neither side alone could achieve the same outcome at this speed.
Limitations and Next Steps
While the results are promising, several factors remain under evaluation:
- consistency of recycled fiber properties
- scalability across different product types
- long-term durability in structural applications
These will determine how far recycled carbon fiber can expand beyond:
- pultruded profiles
- semi-structural components
Final Insight: Circular Composites Are Entering Production Reality
For years, composite recycling has been discussed as a future necessity.
This project shows that:
The transition has already started—at least in specific, well-controlled applications.
Pultrusion provides a practical pathway because it:
- simplifies geometry
- stabilizes process conditions
- allows controlled integration of recycled material
The next step will be extending this approach into:
- more complex structures
- higher-performance applications