Fraunhofer and Toyota Industries Test 100% Recycled Carbon Fiber Spun Yarn

Fraunhofer IGCV is working with Toyota Industries to process 100% recycled carbon fiber spun yarn using wet compression molding, infusion, and prepreg. The yarn is made by adapting cotton spinning methods to reclaimed carbon fiber, so it can run on the same equipment as virgin fiber. Toyota estimates that skipping the calcination step avoids about 80% of the CO2 emissions tied to virgin fiber production. Early results show composites made with the rCF yarn reach roughly 70% of virgin tensile strength and 90% of elastic modulus. Fraunhofer is now looking for European partners in industry and research to expand applications. This builds on earlier rCF work, including a recycled automotive door panel and automated fiber placement trials. The open question is how spun yarn behavior translates from test coupons to production parts, especially for structural uses. If mechanical results and process economics hold up, rCF yarn could give more manufacturers a practical path to lower-impact composites.