Bridging the Gap Between Composite Performance and Sustainability with Surfacetec™ – An Interview with Tom Sharrock

I have worked in composites for over 13 years, primarily focusing on aerospace across Europe and Asia. In this time, I’ve seen an increased interest in closed-loop recycling and the full lifecycle of carbon fibre. At James Cropper, I am keen to help our customers reduce their carbon footprint by integrating sustainable and recycled materials into their composite structures.

Carbon fibre offers unique properties, including being lightweight, having a high tensile strength, high temperature tolerance and low thermal expansion, making it ideal for composite applications in aerospace, automotive, sporting goods, wind energy and many other industries.

However, the challenge arises at the end of the product’s lifespan, where with over 40% of carbon fibre ending up in landfill, managing its lifecycle is a major concern, something in which the composites industry has been trying to address over the past few years.

To address this, James Cropper has developed a recycled carbon veil made from reclaimed fibre sourced from the composite manufacturing supply chain.

At James Cropper, we believe that sustainability and performance should go hand in hand. Our recycled carbon veils provide a solution that meets the demanding performance standards required by industries like aerospace, automotive and sporting goods, while significantly reducing the environmental impact. By recycling carbon fibre and reusing it in applications where it’s needed most, we’ve developed a product that delivers the same high strength, thermal resistance and lightweight characteristics as virgin fibre, but with a dramatically reduced CO2 footprint.

James Cropper’s Technology team has been at the forefront of this innovation for over 15 years. Leveraging our expertise in nonwoven technology to develop high-quality veils with reclaimed carbon fibre sourced from the composite manufacturing supply chain. By using by-products like end of tow bobbins or woven fabric offcuts, we’re able to transform what was once considered waste into a valuable, high performance material. The result is a veil that is easily integrated into a composite layup, that can act as a surfacing or semi-structural layer, with properties that include facilitating a high-quality resin-rich surface finish, as well as imparting electrical conductivity, and high temperature & chemical resistance. 

We’re effectively closing the carbon fibre lifecycle loop, helping the industry move towards a circular economy without compromising on the performance that is critical for these demanding applications.

Our recycled carbon veils offer the same high-performance characteristics as virgin carbon fibre, but with a significantly lower environmental impact. In aerospace, for instance, where safety and precision are paramount, these veils are ideal for non-structural applications, such as interiors for aircraft or eVTOL (electric vertical take-off and landing) components. The veils help reduce weight, improve surface finish and contribute to overall efficiency while maintaining the required structural integrity and thermal resistance.

By using recycled carbon veils, manufacturers can achieve up to a 90% reduction in CO2 emissions compared to virgin carbon fibre, making it an excellent alternative that meets stringent industry requirements without compromising on performance.

While aerospace is a key application, we’re seeing growing in interest in other sectors, such as automotive, renewable energy, marine and sporting goods. In automotive, for example, the ability to reduce the weight of the vehicle directly impacts fuel efficiency and emissions reduction. Similarly, in renewable energy, using lighter, more durable materials can improve the performance and longevity of wind turbine components. By closing the carbon fibre lifecycle loop and repurposing materials that would otherwise go to waste, manufacturers across multiple industries can contribute to sustainability while enhancing their products’ performance.

The composites industry overall maintains as restless spirit of continuous new product development. At James Cropper, we continue to innovate, alongside our recycled carbon veils, we’ve developed a range of sustainable nonwovens. By using naturally derived and recycled fibres, we’re pushing the boundaries of what is possible in sustainable nonwovens, ensuring a brighter and more eco-conscious future for the industry.