Carbon fiber is everywhere, from high-performance bikes to aerospace and automotive parts. But with that comes a major problem: waste. Every year, around 62,000 tonnes of carbon fiber end up as scrap, much of it from industries like aerospace and wind energy. And unlike other materials, carbon fiber doesn’t just break down or get easily repurposed. It is commonly estimated that around 30% of produced carbon fiber ends up as waste.
Recycling carbon fiber isn’t as simple as melting down aluminum or reshaping plastic. Post-consumer waste is tough to recover because the fibers are embedded in resins that make them difficult to separate. The most common recycling methods today, like pyrolysis (burning off the resin), often damage the mechanical properties of the fiber. That’s why many companies still opt for virgin carbon fiber, even though it’s resource-intensive to produce.
Chemical recycling has been explored as an alternative, but it’s expensive, energy-hungry, and inefficient. In many cases, the cost of recycling outweighs the benefits, making it more practical to use new carbon fiber rather than recycled materials.
But what if there was a way to recover carbon fiber without compromising its strength and quality? A method that allows manufacturers to close the loop and reuse carbon fiber in their own supply chains? That would be a no-brainer.
Regulations are already pushing for change. The EU’s End-of-Life Vehicle Directive is just one example, requiring automakers to recycle more materials from their cars. But the industry still lacks scalable, high-quality recycling solutions. The challenge goes beyond meeting sustainability goals- it’s about finding a way to make recycling actually work for manufacturers.
Right now, the industry is at a turning point. The companies that figure out how to keep carbon fiber in the loop without sacrificing performance or cost will be the ones leading the way. The question is: who’s ready to make it happen?
This piece has been made with Carbon Cleanup’s Fiber Needles™, giving the piece a unique look on top of stiffness and durability. The result: carbon optics, zero footprint.
In a transitional phase like this, our approach to cracking the economical formula of closed loop solutions, is to take one piece at a time and in the end close the loop on all materials within the supply chain. However, the impact of one single piece already makes a huge difference- for the planet and the bottom line.
By using recycled carbon fiber inserts, manufacturers can cut CO₂ emissions by up to 95% (compared to the use of virgin carbon fiber), as seen in our collaboration with KTM Technologies. That’s the equivalent of preventing 76.7 tons of CO₂ from entering the atmosphere. That’s about the same as driving a car 10 times around the earth or the annual emissions of 10 households.
Beyond environmental benefits, the cost savings are just as compelling.
Closing the Loop on CF and PP at KTM Technologies
Carbon fiber is incredibly strong and lightweight, meaning far less material is needed compared to traditional options. This translates into lower production costs and reduced material waste. Sourcing recycled carbon fiber can reduce raw material costs by up to 30%, depending on production volume. And when manufacturers close the material loop, procurement becomes more predictable, reducing price volatility and supply chain risks.
Sustainability and performance don’t have to be a trade-off. By combining recycled carbon fiber with advanced manufacturing technologies like KTM Technology’s Conexus, manufacturers can create lighter, stronger, and more cost-efficient components, without compromising on quality.
This brake disc guard, for example, was originally made with virgin PA and ABS, chosen for higher impact resistance and color brilliance. Now, by using in-house recycled materials, it’s more cost-effective, has a lower carbon footprint, and still delivers the same high performance.
This brake disc lever is made from recycled carbon fiber (CF) and polypropylene (PP). By using CF throughout the whole vehicle (instead of a mixture of glass fiber and carbon fiber), choosing a monomaterial approach (all carbon fiber) makes the part fully recyclable, supporting a circular economy.
Weight is everything in automotive design- both for performance and footprint. The lighter the part, the lower the CO₂ emissions over a vehicle’s lifetime. For this part, the recycled CF-reinforced PP maintains the same weight as virgin materials while cutting environmental impact.
This brake disc lever offers the strength of carbon fiber without the high cost and environmental impact of virgin CF. Made with Carbon Cleanup’s recycled CF, it cuts material costs while keeping performance at the highest level. KTM Technologies’ Conexus bonding process ensures a smooth transition to recycled materials, making it a scalable, cost-efficient, and fully recyclable solution
This approcach enables you to meet sustainability goals, reduce material costs, and maintain top-tier performance, all while positioning your brand as a bold player in circular design. With Carbon Cleanup and KTM Technologies, you get cutting-edge sustainability without compromise.
A move toward sustainability is never just about the material- it’s an invitation to rethink the entire product. And when you do that, innovation happens faster than you think." - Hans Lochner (KTM Technologies)
This seat was the first part developed in collaboration with KTM Technologies, ENGEL, and Carbon Cleanup, and therefore it symbolizes the power of choosing sustainability as a strategic advantage.
Sustainability isn’t just about reducing waste- it is about preparing for a future we all know has already started: the next era of manufacturing. That includes rethinking materials, refining processes, and embracing circularity. And for those who lead the charge, the benefits go beyond environmental impact:
Achieve weight reduction without sacrificing strength. Thanks to uniformly distributed fibers, thinner parts maintain structural integrity, delivering carbon fiber performance at the cost of glass fiber. Traditionally done with glass, this approach now unlocks new possibilities with recycled carbon fiber.
Lighter parts mean lower material usage and reduced production costs. Recycled carbon fiber provides a cost-effective alternative to virgin materials, while efficient processing minimizes waste and optimizes manufacturing efficiency.
Sustainability regulations are tightening worldwide. Choosing recycled, recyclable, and compliant materials ensures long-term viability while helping companies meet evolving industry standards without last-minute adaptations.
The next era of manufacturing is already here. The only question is: Are you leading it?
Instant CO2 savings by using 100% recycled CF instead of virgin CF