COMPOSER

Relevance of the project

In the context of structural plastics, the use of reinforced polymers has gained increasing importance in the past few decades in several manufacturing sectors. In particular, thermosetting carbon-fiber reinforced composites (CFRCs) have recently become leading contenders in a large number of industrial applications where lightness represents an asset, including transportation (automotive, aerospace), construction (building and infrastructures, wind turbines) and consumer/sporting goods.
With growing amounts of CFRCs being used worldwide, the corresponding waste materials, including manufacturing off-cuts, scraps and end-of-life (EoL) components, are slowly but steadily reaching significant levels. This scenario has raised environmental and economic awareness on the need for sustainable routes for CFRC waste management and valorization, also in view of the high economic value of CFRCs on a global scale. At present, CFRC waste management is typically based on landfill disposal or incineration. However, the economic costs of such approaches are becoming increasingly high. In addition, major environmental concerns have led to strict management conditions with respect to composite waste, especially in the EU (e.g., directives 1999/31/EC and 2000/53/EC). As a result, the definition of a correct waste management strategy accomplishing the transition from a linear to a circular economy represents an impelling issue for both business and environment.
Within this framework, recent progresses in organic and polymer chemistry offer innovative pathways that may help to improve CFRC EoL and waste management through the incorporation of intrinsic de/remanufacturing functionalities in CFRCs at the material design and production stage. In particular, the use of dynamic crosslinking bonds in the macromolecular network of thermosetting materials has been recently introduced as powerful chemical tool to equip thermosets with new thermally-triggered functionalities potentially enabling their repairing, welding, reprocessing and reuse. While several examples of such dynamic systems have been demonstrated based on different types of chemistries, the use of such thermally-responsive thermosets in the field of CFRCs has been surprisingly limited, with only a few works directly related to long carbon fiber reclamation or matrix recovery, with these two issues being typically addressed separately. As a result, a holistic approach to treat CFRC waste in its integrity (repair, de/remanufacturing and reuse of CFRC part, full recovery of both CFs and thermosetting matrix) is still lacking, especially within the framework of economically sound and environmentally sustainable circular economy business models.

Approach of the project

In the attempt to fill this gap, COMPOSER project targets CFRC de/remanufacturing as a whole by demonstrating a systemic approach for CFRC EoL/waste recovery and valorization based on the implementation of a series of innovative actions at material, technology and business level. COMPOSER project exploits the concept of dynamic covalent chemistry recently introduced in the scientific literature to develop new smart polymeric systems to be used as matrix components in CFRCs successfully exhibiting multiple repair, reuse and de/remanufacturing capabilities when heated at specific processing temperatures, without affecting their usability and functionality.

Material level

Design and development of novel matrix materials enabling CFRC repair and de/remanufacturing for reuse.

Technology level

Set-up and optimization of efficient repair and demanufacturing technologies as well as suitable inspection protocols based on non-destructive analysis of CFRC parts.

Business model level

Set-up of circular economy oriented business models based on relevant CFRC supply chains through the analysis of different reverse logistic options.

Multidisciplinary approach

Throughout the course of COMPOSER, a clear multidisciplinary approach is sought so as to ensure full exploitation of the scientific, technological and economic advancements in a truly holistic yet strongly methodological fashion. In order to do so, all actions are performed synergistically among the research partners involved in the project (Politecnico di Milano (POLIMI) - Department of Chemistry, Materials and Chemical Engineering “Giulio Natta” and Mechanical Engineering Department – and Istituto di Tecnologie Industriali e Automazione – Consiglio Nazionale delle Ricerche (ITIA-CNR)), relying on continuous feedback and mutual exchange of information.