Leave No Trace Selects Mountain Hardwear For Corporate Partner Of The Year 2024

RICHMOND, Calif. — December 6, 2024 — Mountain Hardwear is proud to announce it has been named the 2024 Leave No Trace Corporate Partner of the Year. This distinction honors the company’s relentless commitment to environmental stewardship and its proactive role in promoting sustainable outdoor practices. This recognition highlights Mountain Hardwear’s significant contributions over the past year, the brand’s second year of partnership with Leave No Trace.

Mountain Hardwear’s efforts to advance environmental awareness have been wide-ranging— from leveraging its global platform to raise the profile of Leave No Trace principles, to engaging directly with communities on conservation projects.

One of the key achievements for Mountain Hardwear in 2024 was co-leading a major volunteer initiative with the brand’s employees in the Bay Area, where more than 100 hours of service were dedicated to hands-on environmental work. This initiative benefitted local ecosystems and demonstrated Mountain Hardwear’s dedication to engaging outdoor enthusiasts in stewardship activities.

In addition to its volunteer efforts, Mountain Hardwear played an integral role in supporting the expansion of Leave No Trace’s ambassador program. Leave No Trace welcomed Mountain Hardwear mountaineering athletes Scott Lehmann and Shayna Unger as Leave No Trace Ambassadors. Working together with Mountain Hardwear and Leave No Trace, these influential athletes are helping to amplify the message of responsible outdoor practices to a broader audience, inspiring others to incorporate LNT principles into their outdoor adventures.

Mountain Hardwear also continued its tradition of outdoor education by co-presenting at major outdoor festivals throughout the year. These events allowed Mountain Hardwear to reach thousands of festival-goers, offering free education on Leave No Trace principles and encouraging attendees to adopt sustainable practices when exploring the outdoors. By providing this valuable resource to outdoor communities, Mountain Hardwear, in partnership with Leave No Trace, continues to reinforce their role as leaders in environmental education.

As a featured sponsor of the Leave No Trace Global Summit, Mountain Hardwear helped celebrate the organization’s 30th anniversary while paving the way for its next 30 years of impact. The summit served as an important milestone for Leave No Trace, and Mountain Hardwear’s involvement further demonstrated its long-term commitment to supporting environmental initiatives and sustainability within the outdoor industry.

“Mountain Hardwear’s connection with the leading environmental education organization allows our shared missions to be amplified — empowering more people to experience and connect with nature while becoming more conscious stewards and to protect our wild spaces. We are proud to partner with Leave No Trace and receive this recognition,” said Kathryn Luna, senior brand marketing specialist — Community & Partnerships.

“Our work with Mountain Hardwear exemplifies the power of partnership in achieving meaningful change. Mountain Hardwear’s dedication to environmental stewardship and engaging communities has amplified Leave No Trace’s mission to protect and enjoy the outdoors responsibly. Together, we’re inspiring a new generation of outdoor enthusiasts to become lifelong stewards of our natural world,” said Dana Watts, Leave No Trace executive director

Looking ahead, Mountain Hardwear is excited to announce a new collaboration with Leave No Trace. The Leave No Trace x Mountain Hardwear logowear collection, set to launch this upcoming spring, will combine innovative design with a focus on sustainability, further advancing the shared mission of promoting environmental responsibility within the outdoor community.

For more information about the 2024 Leave No Trace Corporate Partner of the Year Award, visit Leave No Trace Awards 2024. To learn more about Mountain Hardwear and its award-winning products, please visit www.mountainhardwear.com.

Posted: December 9, 2024

Source: Mountain Hardwear, Inc.

NRF: Import Cargo Rising as Higher Tariffs and Potential Port Strike Approach

WASHINGTON — December 9, 2024 — With a strike possible again next month at East Coast and Gulf Coast container ports and President-elect Donald Trump planning to increase tariffs, the nation’s major container ports are expected to see a continued surge in imports through next spring, according to the Global Port Tracker report released today by the National Retail Federation and Hackett Associates.

“Either a strike or new tariffs would be a blow to the economy and retailers are doing what they can to avoid the impact of either for as long as they can,” NRF Vice President for Supply Chain and Customs Policy Jonathan Gold said. “We hope that both can be avoided, but bringing in cargo early is a prudent step to mitigate the impact on our industry, consumers and the nation’s economy. We call on both parties at the ports to return to the table, get a deal done and avoid a strike. And we call on the incoming administration to use tariffs in a strategic manner rather than a broad-based approach impacting everyday consumer goods.”

Talks have broken down between the International Longshoremen’s Association and the U.S. Maritime Alliance, leaving the potential for a strike after the current contract extension reached after a three-day strike in October expires January 15. NRF last week led a coalition of trade associations in sending a letter asking both parties to return to the bargaining table. Meanwhile, Trump has said he plans to increase a wide range of tariffs once he takes office on January 20.

Hackett Associates Founder Ben Hackett said retailers are under pressure as they frontload cargo to avoid both the disruption of the strike and higher costs from the tariffs.

“Prospects of reaching a quick agreement on the key sticking point of automation are not looking good,” Hackett said, referring to the port labor contract. “The window to frontload goods on vessels arriving before a potential strike is quickly closing. Then there are issues as President-elect Trump promises to increase tariffs when he takes office. It is not clear whether this will actually take effect immediately or whether it will take time to implement the tariffs, but shippers are moving up as much cargo as they can before then.”

U.S. ports covered by Global Port Tracker handled 2.25 million Twenty-Foot Equivalent Units – one 20-foot container or its equivalent – in October, although the Port of Miami has yet to report final data. That was down 1.2% from September but up 9.3% year over year.

Ports have not yet reported November’s numbers, but Global Port Tracker projected the month at 2.17 million TEU, up 14.4% year over year. December is forecast at 2.14 million TEU, up 14.3% year over year. That would bring 2024 to 25.6 million TEU, up 14.8% from 2023. Before the October strike and November’s elections, November had been forecast at 1.91 million TEU and December at 1.88 million TEU, while the total for 2024 was forecast at 24.9 million TEU.

January 2025 is forecast at 2.2 million TEU, up 12% year over year; February at 1.87 million TEU, down 4.1% because of fluctuations in the timing of Lunar New Year shutdowns at Asian factories; March at 2.17 million TEU, up 12.7%, and April at 2.15 million TEU, up 6.6%.

Global Port Tracker, which is produced for NRF by Hackett Associates, provides historical data and forecasts for the U.S. ports of Los Angeles/Long Beach, Oakland, Seattle and Tacoma on the West Coast; New York/New Jersey, Port of Virginia, Charleston, Savannah, Port Everglades, Miami and Jacksonville on the East Coast, and Houston on the Gulf Coast. The report is free to NRF retail members, and subscription information is available at NRF.com/PortTracker

As an authority and voice for the retail industry, NRF analyzes economic conditions affecting the industry through reports such as Global Port Tracker.

Posted: December 9, 2024

Source: The National Retail Federation (NRF)

Myant And Coapt Partner To Transform Assistive Technology And Pain Management With Textile-Based Neural Interfaces

TORONTO — December 5, 2024 — Myant Corp., a developer of textile computing for healthcare, and Coapt, a supplier of neural interface technology, announced a collaboration aimed at transforming the assistive technology landscape. The partnership will focus on developing and commercializing textile-based electromyography (EMG) interfaces, enhancing the way prosthetic limbs and related therapeutic devices interact with the human body.

In merging Coapt’s cutting-edge EMG intent decoder control systems with Myant’s advanced textile technologies, this collaboration seeks to bring forward new products that will provide more comfort, precision, and control for individuals using assistive devices such as prosthetic limbs. Products born from this partnership may open new pathways for therapies that target phantom limb pain and biofeedback-based solutions, further advancing Myant’s mission to improve life and everyday experiences for those with unique needs.

“Myant and Coapt share a vision of improving quality of life through seamless integration between technology and the human body,” said Tony Chahine, CEO at Myant. “This collaboration will push the boundaries of what is possible in prosthetics and rehabilitation.”

Myant and Coapt’s roadmap for future innovation in assistive technology includes the exploration of virtual and augmented reality applications for medical therapies. This venture will also include funded research and clinical trials to explore the broader implications of their combined technologies for patients worldwide.

“Together, Coapt and Myant are creating a future where assistive technology not only helps people regain function, but also improves their overall comfort and autonomy,” added Blair Lock, CEO at Coapt.

Myant is excited to showcase its latest innovations at the Consumer Electronics Show (CES) on January 7-10, 2024 in Las Vegas. Through live demos with Coapt, Myant aims to accelerate the adoption of next-generation assistive technologies and foster meaningful connections with the global healthcare community.

Posted: December 5, 2024

Source: Myant / Coapt

Rubi Secures $1 Million Phase II Grant From The National Science Foundation To Scale Its Breakthrough Carbon-To-Cellulose Platform

SAN FRANCISCO — December 5, 2024 — Rubi, a company reinventing manufacturing to be symbiotic with the planet, has been awarded a $969,961 Small Business Innovation Research (SBIR) Phase II grant from the National Science Foundation (NSF) to develop and scale its carbon-to-cellulose platform. This prestigious grant, awarded to less than 5 percent of SBIR applicants over the last decade, recognizes Rubi’s groundbreaking advancements in CO2-to-materials technology and will support the company’s path to commercialization.

Rubi has pioneered a first-of-its-kind cell-free biocatalysis technology to make CO2-derived materials and chemicals. The company’s initial focus is on CO2-derived cellulose to replace traditional wood pulp, aiming to decarbonize textile production by eliminating deforestation and significantly reducing the environmental impact of raw material manufacturing. With proven technology and strong customer partnerships, the nearly $1 million grant accelerates Rubi’s mission to meet the urgent global demand for low-carbon materials.

The rare NSF grant will support the commercialization of Rubi’s groundbreaking CO2-to-materials technology.

The NSF Phase II award builds on Rubi’s successful Phase I grant completion in 2023, which advanced multi-enzyme cascade design and enzyme stabilization for carbon-to-cellulose production. Since then, Rubi’s milestones include:

  • An $8.7 million seed funding round, co-led by H&M Group and Patagonia;
  • Strategic pilot partnerships with global fashion brands H&M, Patagonia, Reformation, GANNI, and Nuuly;
  • A series of pilot projects in collaboration with Walmart;
  • Debuting the world’s first yarn made from CO2 through a fully enzymatic process with Ganni; and
  • Recognition from Fast Company’s World Changing Ideas, TIME’s Top Greentech Companies, Business of Fashion 500, Vogue Business 100, and Forbes 30 Under 30 lists.

“This award is a testament to Rubi’s vision for a symbiotic manufacturing future and our ambition to lead the next era of sustainable industry,” said Neeka Mashouf, Co-Founder and CEO of Rubi. “As we move into 2025, this grant will accelerate our efforts to scale CO2-derived, low-carbon cellulose for the textile industry, ultimately allowing us to transform environmental challenges into opportunities, bridge our proven science with existing supply chains, and set a new standard for decoupling industrial growth from environmental degradation.”

“NSF accelerates the translation of emerging technologies into transformative new products and services,” said Erwin Gianchandani, NSF Assistant Director for Technology, Innovation and Partnerships. “We take great pride in funding deep-technology startups and small businesses that will shape science and engineering results into meaningful solutions for today and tomorrow.”

Rubi’s proprietary technology uses a cascade of specialized enzymes to transform simple 1-carbon molecules into complex carbohydrate polymers like cellulose under mild conditions. Compared to traditional methods such as fermentation or chemical catalysis, which are constrained by cost, efficiency, or product range, Rubi’s cell-free enzymatic platform can achieve a 10x reduction in capital costs and 3x higher yields than fermentation and significantly lower energy use than chemical catalysis while expanding the range of attainable products.

Unlike cell-based fermentation — which requires energy-intensive conditions to sustain living organisms and typically generates over 70 percent byproduct waste — Rubi’s cell-free biocatalysis process can convert nearly all carbon inputs into the desired product. This maximized efficiency eliminates the significant resource demands of conventional biological methods.

“Rubi’s cell-free biocatalysis approach is a paradigm shift in manufacturing, providing a sustainable and efficient solution to produce CO2-derived materials without exploiting natural resources. By producing forest-free cellulose in hours rather than decades and with drastically reduced carbon emissions, water usage, and land impact, Rubi offers a faster, more sustainable alternative to traditional wood pulp,” said Dr. Leila Mashouf, M.D., co-founder and CTO of Rubi. “We’re thrilled to have the continued support of the NSF with this Phase II award and look forward to scaling our technology to meet the growing global demand for ultra-low-carbon, bio-based materials.”

Posted: December 5, 2024

Source: Rubi

Envalior And Ford Win SPE Automotive Award For Most Innovative Use Of Plastics 

LIVONIA, Mich. — December 5, 2024 — Envalior, in collaboration with Ford Motor Co., has been honored with the Most Innovative Use of Plastics award in the “Materials” category at the 53rd Annual SPE Automotive Innovation Awards Competition & Gala. This highly regarded event, held at Laurel Manor in Livonia, Mich., celebrates groundbreaking achievements in automotive plastics.

Left to right: Corey Brown (Sogefi), Isaiah Nordland (Viking Plastics), Taneisha Deans (Envalior), Alec Grazier (Viking Plastics), Gianluca Mantovano (Ford Motor Co.), Davide Preti (Envalior), Suresh Shah (SPE Board), Justin Gilbert (Envalior), Russ Bloomfield (Envalior), Jose Chirino (Envalior), Travis Collings (Ford Motor Co.), Jean Seibold (Envalior).

The award recognizes the development of a re-engineered Exhaust Gas Recirculation (EGR) Cold Tube and diffuser, a critical component designed by Ford. By replacing Stainless Steel, with Envalior’s advanced Xytron™ PPS thermoplastic material, the application realized a 28 percent part weight reduction and achieved superior chemical resistance to withstand extreme environments for long-lasting performance.

With Xytron, the EGR Cold Tube and diffuser can now withstand a highly acidic environment with pH levels of 2.2 and temperatures up to 200°C. Furthermore, the new design eliminates the need for multiple components, including a gasket, O-ring and fasteners, resulting in a greatly simplified part that directly integrates into the air intake assembly. This sets a new standard for EGR system efficiency, greatly simplified manufacturing and assembly processes, and significant cost savings.

“This award validates Envalior’s commitment to material innovation and the collaborative expertise of our team,” said Russ Bloomfield, Application Development engineer at Envalior. “It highlights the power of partnerships between Envalior, Ford Motor Company, Sogefi, and Viking Plastics.”

Envalior also extends its congratulations to its partners, Sogefi and Viking Plastics, for their vital roles in this achievement. Sogefi serves as the Tier 1 supplier for the EGR assembly, while Viking Plastics molds the Xytron EGR Tube supplied to Sogefi.

“This recognition underscores Envalior’s dedication to pushing the boundaries of innovation and fostering successful collaborations,” added Grace Showalter, Regional Commercial Director – Americas at Envalior. “We are incredibly proud of our team and partners for achieving this milestone.”

Posted: December 5, 2024

Source: Envalior

S&S Activewear Rolls Out Robotic PopPick System In Reno, Reading Distribution Centers

RENO, Nev. & READING, Pa. — December 5, 2024 — S&S Activewear, a technology-enabled distributor of apparel and accessories, announced it has scaled up its partnership with Körber Supply Chain Software (Körber) and Geek+ Robotics to optimize its warehouse operations in Reno, Nevada, and Reading, Pennsylvania, with the roll-out of autonomous robotic picking solutions.

S&S has introduced more than 200 robots to both its 800,000-square-foot facility in Reno and its 650,000-square-foot warehouse in Reading. Both distribution centers house 2,750 racks storing 110,000 totes. The Reno facility’s automation system debuted in the summer, followed by Reading in the fall. Both facilities are now operating at full capacity. The deployment of the new system — first introduced at S&S’s Lockport, Ill., warehouse earlier this year — will increase the speed and accuracy of customer orders.

“Since deploying the PopPick system in our Illinois distribution center, we’ve not only seen production rates jump from 40 picks per hour to 150 picks per hour and a drastic increase in picking accuracy, but turnover has also decreased by 75 percent as many of the typical warehouse safety risks have been reduced or eliminated,” said Brian Beale, CTO of S&S Activewear. “We expect to see similar results as we integrate the PopPick system into our operations at our Reno and Reading facilities.”

The company’s implementation was recently honored with the NextGen End User Award for Robotics. S&S was also named to Inc.’s Best in Business 2024 list for Operational Excellence. S&S plans to roll out the automation system in more distribution centers in 2025.

“Our expanded use of automation and robotics technologies demonstrates the strength of our commitment to our customers and our employees,” said Frank Myers, CEO of S&S Activewear. “We’re able to fulfill customer orders in a fraction of the time required with legacy systems while also creating a safer, more streamlined environment for our employees.”

Posted: December 5, 2024

Source: S&S Activewear

Dovetail Workwear And TREW Gear Launch The Ultimate Women’s Winter Bib

PORTLAND, Ore. — December 5, 2024 — Dovetail Workwear and TREW Gear, two brands known for technical innovation and performance materials, have joined forces to create the perfect combination of an extreme-temperature work overall that doubles as a durable and functional snowsports bib.

Combining TREW’s technical snow gear expertise with Dovetail’s women-focused workwear design, the Rock Creek Work Bib (MSRP $599) is made for women who brave harsh winter conditions for work and play. The limited-edition winter bib is available in two colorways with sizes ranging from XS-4XL in multiple inseam options.

Designed in conjunction from insights of the women-run snow operations resort staff on Mt. Hood and Mt. Baker, and informed with feedback from Dovetail’s extensive wear testing teams of farmers in the Midwest to women working in the US Antarctic research program including McMurdo Station, the Rock Creek Work Bib is a beautiful testimonial to the common challenges of cold weather work and the lack of viable options for women.

“Finding the common issues across these types of environments and solving them is a designer’s dream. By using zonal reinforcement and zonal insulation, we were able to create a durable piece that is still the perfect weight and allows for maximum mobility. My favorite part was creating a pocketing system that works for a ski patroller or the scientific gear of a penguin researcher in Antarctica” says Sara DeLuca co-founder and VP of Product at Dovetail Workwear.

The Rock Creek Work Bib unites TREW’s most durable 3-layer, 4-way stretch nylon ripstop laminated fabric with a PFAS-free waterproof breathable membrane with Cold Blocker insulation in the seat and knees to shut out the cold in high-wear areas. Combined with Dovetail’s signature utility pockets for all-around functionality, and true workwear fit and durability, it’s rugged enough to handle harsh environments and flexible enough to move with you. The 20k waterproof and breathability rating keeps wearers warm and dry in harsh conditions, and purpose-built features like radio and tool pockets, adjustable cuffs for ski, snowboard, or work boots, and a drop-seat design for easy access make it ideal for women adventuring on skis, snowboards, and snowmobiles to working in ski patrol, winter agriculture, and other demanding cold-weather jobs.

“We worked with product testers from all over the country who put our prototypes through their paces, wearing them out in the toughest conditions. There was no shortage of insights and ideas throughout the design process, which speaks to both the strength of this concept and the clear need for truly functional, durable, and weatherproof winter bibs tailored for women. This collaboration with Dovetail has allowed us to create gear that fills that gap and meets the demands of the most dedicated outdoor professionals,” said Chris Pew, CEO of TREW Gear.

The bib’s development spanned over 18 months, including over ten rounds of prototypes, and was put through its paces by over 30 wear-testers. The result is a garment with the comfort of classic work overalls and the technical features of top-tier snow bibs. The Rock Creek Work Bib is available now through dovetailworkwear.com, trewgear.com and select retailers nationwide.

Posted: December 5, 2024

Source: Dovetail Workwear

Freudenberg To Introduce Sustainable Innovations For Shoe And Leather Goods At Inspiramais Trade Fair In Brazil

WEINHEIM, Germany — December 5, 2024 — Freudenberg Performance Materials (Freudenberg) will present its full range of high- performance materials for footwear at Inspiramais January 21-22, 2025, in Porto Alegre, Brazil.

Freudenberg’s high performance counterliners Source — ©Freudenberg Performance Materials

The global manufacturer of performance materials will highlight its latest technical and sustainable innovations tailored for the shoe industry, including microfibers, counterliners, liners, interlinings, reinforcements, insoles, and membranes. At Inspiramais, designers and footwear professionals can meet with Brazil-based Freudenberg experts to support them design and develop products in line with the industry’s evolving demands for performance and environmental responsibility.

Freudenberg’s presentation at the event underscores its commitment to innovation and sustainability within the industry. In line with its sustainability goals, Freudenberg has increased the proportion of products in its portfolio that incorporate recycled content and employ solvent-free and binder-free manufacturing processes. The company’s efforts are exemplified by its range of vamp liners, reinforcements, and strobel insoles, which contain between 35% to 100% recycled material. The new insoles and reinforcements for sports shoes have recycled fiber content and provide high tensile and tear resistance at the same time.

Vegan suede

Freudenberg’s vegan suede made from microfiber nonwoven Source — ©Freudenberg Performance Materials

Additionally, Freudenberg is introducing a solvent-free vegan suede material, crafted from microfiber nonwovens, which offers both breathability and versatility in dyeing — a suitable choice for upper and facing in casual and athletic shoes.

Innovations for safety shoes and others

Freudenberg’s advancements also extend to the realm of safety footwear, with the introduction of specialized insoles that are resistant to perforation and suitable for PU injection, as well as electrically conductive.

Freudenberg’s special insoles for safety shoes Source — ©Freudenberg Performance Materials

Moreover, the company has developed breathable waterproof membranes that can be integrated into liners and interliners, enhancing both comfort and protection for safety shoes, boots, and waterproof footwear.

The company’s new range of high performance counterliners is another highlight, designed to cater to a diverse array of footwear categories, including women’s, men’s, children’s, safety shoes, boots, and athletic shoes. These counterliners are distinguished by their breathability, color variety, and superior abrasion resistance.

Posted: December 5, 2024

Source: Freudenberg Performance Materials

Mark Ushpol Appointed EVP, Americas Business Area At Suominen

HELSINKI — December 5, 2024 — Mark Ushpol has been appointed executive vice president, Americas business area at Suominen. He will be a member of Suominen’s Executive Management Team and report to President and CEO Tommi Björnman. Ushpol will start in his new position on January 6, 2025.

Mark Ushpol

Ushpol joins Suominen from Ahlstrom, where he worked as executive vice president of the Food & Consumer Packaging division and as a member of the Executive Management Team.

“Mark has a strong experience in leading industrial business and operations. He also has industry knowledge and proven record in successfully executing company goals. I am sure he will be a valued member in our Executive Management Team and support us in our journey towards profitable growth,” Björnman said.

Posted: December 5, 2024

Source: Suominen Corporation

Tapes Made From Recycled Carbon Fibers For Lightweight Construction

DENKENDORF, Germany — December 5, 2024 — Due to their excellent mechanical properties and low weight, carbon fiber reinforced plastics (CFRP) are increasingly being used in lightweight construction applications where high strength and rigidity combined with minimal weight are crucial. However, the growing use of CFRP is also accompanied by large quantities of carbon fiber waste. So far, only processing routes that significantly reduce the properties of CFRP and thus limit the fields of application have been established. The German Institutes of Textile and Fiber Research Denkendorf (DITF) have developed highly oriented tapes made from recycled carbon fibers (rCF) suitable for reuse in high-performance applications such as structural components in the automotive sector.

Developed “infinity”rCF tape variant with trimming of the tape edges. Photo — DITF

Carbon fibers are usually produced from petroleum-based raw materials in an energy-intensive process that emits large amounts of CO2. The material has a global warming potential of around 20 to 65 kilograms of CO2 equivalents per kilogram. Nevertheless, the production of CFRP continues to increase and with it the amount of CFRP waste. This is because, depending on the processing method, up to 50 percent offcuts are generated during production. In addition, there are large quantities of CFRP waste in the form of components that have reached the end of their service life. In Europe alone, around 8,000 passenger aircraft with cosiderable CFRP content are expected to be taken out of service by 2030.

Currently, only 15 percent of CFRP waste is recycled. The remaining 85 percent of these CFRP components end up in waste incineration plants or landfills at the end of their service life. Incineration can generate energy in the form of heat or electricity. However, recycling carbon fibers would contribute far more to climate and resource protection.

In recent years, various recycling processes for CFRP, such as pyrolysis or solvolysis, have therefore been further developed in order to recover high-quality carbon fibers.

Compared to virgin fibers, the possible uses of recycled carbon fibers are significantly limited. In a virgin fiber product, carbon fibers are usually present in filament strands of technically unlimited length and oriented in the direction of the load. In this way, the carbon fiber unfolds its full potential, as it has its maximum strength in the fiber direction. Recycling inevitably results in a shortening of the carbon fibers to lengths in the micrometer to centimeter range. In addition, the orientation of the carbon fibers is lost and the fibers are initially in a tangled position.

The DITF have been successfully working for around 15 years on adapting classic spinning processes to the new fiber material rCF. The aim is to develop a new category of rCF semi-finished products and improve their mechanical properties so that they can actually replace virgin fiber material in structural applications. Only then will carbon fiber-based composite materials be truly recyclable.

In order to produce an oriented semi-finished product similar to a carbon product from virgin fibers, it is crucial to eliminate the tangled position of the rCF and to align the fibers parallel to each other. One promising way of achieving this is the production of highly oriented tapes.

In a first step, the carbon fibers are opened and mixed with thermoplastic matrix fibers (polyamide 6). The fiber mixture is then further separated and oriented in a carding process modified for the processing of carbon fibers. At the outlet of the carding machine, the fiber card web produced in the carding process is combined into a fiber sliver and deposited in a can. This rCF/PA6 fiber sliver is the starting material for the subsequent tape forming process and already has a pre-orientation of the carbon fibers. The orientation of the fibers can be increased in the subsequent drawing process. By drawing the fiber tape, the fibers are moved in the direction of draft and aligned longitudinally. The final process step is tape formation, in which the fiber tape is under tension formed into the desired shape and then fixed into a continuous tape structure. During fixation, the thermoplastic fibers melt partially or completely and then solidify.

This technology developed at the DITF for the production of highly oriented rCF tapes was used as part of the “Infinity” research project (03LB3006) to demonstrate a sustainable and fiber-friendly recycling cycle for CFRP. Based on the “Infinity” tapes, a composite material was developed that achieved 88 percent of the tensile strength and tensile modulus of a comparable virgin fiber product. In addition, a life cycle analysis showed that the global warming potential is reduced by approx. 49 percent when using pyrolysis fibers and by approx. 66 percent for rCF from production waste.

The findings thus illustrate a way towards true substitution of virgin fiber CFRP with recycled CFRP instead of downcycling to low-orientation materials and the associated loss of mechanical properties.

Posted: December 5, 2024

Source: Deutsche Institute für Textil- und Faserforschung (DITF)

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