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Although fiber-reinforced plastics combine high strength and stiffness with being lightweight, major difficulties arise with high volume production and the return of manufactured parts back into the cycle of materials at the end of their lifecycles. In a novel approach, structural parts were produced from recycled material while utilizing the so-called injection molding compounding process. Recycled fibers and recycled polyamide matrix material were used by blending carbon and matrix fibers into a sliver before processing. Injection molding was then used to produce long fiber-reinforced parts through a direct fiber feed system. Recycled matrix granules were incorporated into the injection molding process by means of an injection molding compounder to investigate their influences on the mechanical properties of the parts. The findings show that the recycled fibers and matrix perform well in standardized tests, although fiber length and fiber content vary significantly and remain below expectations.

Insights into the Processing of Recycled Carbon Fibers via Injection Molding Compounding