National University of Singapore (NUS) Develops Innovative Recycling Method Converting Carbon Fiber Composite Waste into Functional Aerogels

August 23, 2026

Jota Machinery Singapore

Overview

Researchers at the National University of Singapore (NUS) have developed a groundbreaking recycling method to convert carbon fiber reinforced epoxy composite waste into lightweight aerogels, suitable for applications such as thermal insulation, sound absorption, and oil spill cleanup. The process utilizes both carbon fiber and epoxy components from the waste, pulverizing it, mixing with a cellulosic binder, and then freeze-drying to create porous aerogels. This technology holds significant implications for accelerating the transition of high-value composites towards a circular economy.

In Depth

Key Findings

Researchers at the National University of Singapore (NUS) have developed an innovative recycling method that transforms high-value carbon fiber reinforced epoxy composite (CFRP) waste into lightweight aerogels, suitable for diverse applications including thermal insulation, sound absorption, and even oil spill cleanup. This achievement represents a major breakthrough in addressing composite material waste issues and promoting resource efficiency.

Technical / Clinical Details

The recycling process developed by the NUS research team first involves pulverizing discarded CFRP, thereby efficiently utilizing both the carbon fiber and epoxy resin components. This fine powder is then mixed with a cellulosic binder, and subsequently, a specialized freeze-drying process forms a highly porous, extremely lightweight aerogel structure. Due to its unique nanoporous architecture, this aerogel exhibits excellent thermal insulation and sound absorption properties. Furthermore, its combined hydrophobic and oleophilic characteristics have been confirmed to efficiently adsorb and remove oil spills from water bodies. While conventional CFRP recycling methods primarily focused on carbon fiber recovery, often discarding the epoxy resin matrix, this new technology successfully extracts maximum value from both components.

Background & Context

Carbon fiber composites are widely used as high-performance materials in industries such as aerospace, automotive, and wind energy. However, their complex structure makes recycling extremely challenging, leading to a growing waste problem. Most end-of-life CFRP is either landfilled or incinerated, posing significant environmental burdens and resource wastage. This NUS technology offers a sustainable solution to these challenges, paving the way for the reintegration of high-value carbon fibers and epoxy resins into a circular economy system. This represents a crucial advance for the entire composite materials industry in reducing its environmental footprint and enhancing sustainability.

Strategic Significance & Outlook

The technology developed by NUS for producing aerogels from CFRP waste is expected to find applications across a wide range of industrial sectors. Potential uses include thermal and acoustic insulation in construction, oil spill remediation as an environmental cleanup material, and lightweight structural components for automotive parts or electronic devices. Future work will likely focus on validating the industrial scalability of this technology and optimizing manufacturing costs. This recycling breakthrough has the potential to bring an innovative solution to the waste problem faced by the composite materials industry, making a significant contribution to a more sustainable society.

Source: https://jotaintl.com/category/global-composite-material-news/carbon-fiber-composite-waste-aerogel/

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