Composite materials are valued for their high stiffness, strength, and low density, offering durability, which makes them a popular choice for sustainable design. However, recycling composites at the End-of-Life (EoL) remains a challenge, particularly for thermoset composites. While bio-based composites reduce CO₂ emissions, and reduce dependence on fossil resources, they are not infinitely available.
This study used the Material Driven Design method to explore EoL reprocessing options for flax/furan composites, incorporating mechanical and user experience tests. A recycling process based on intentional delamination was identified, enabling recovery of oriented long fibre mats for re-use. To demonstrate its technical feasibility, a car dashboard for the Ecorunner car was designed and produced using recycled flax/furan composite material. The tensile strength of material patches ranged from 70-118 MPa, with Young’s modulus of 9-24 GPa.
The dashboard production and user tests confirm the potential for multiple-use cycles of the flax/furan composite. This research demonstrates a novel recycling process for flax/furan composites, and shows how it can be integrated into industrial applications, offering valuable insights into the challenges and opportunities of recycling composite materials. As composite recycling methods continue to develop, these findings can stimulate further uptake of sustainable materials in the composite industry.