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ENGINEERING QUESTIONS/OBJECTIVES The choice of materials for semi-structural and structural parts has historically been driven by a compromise between cost, quality, and performance. The choice to use composites in automotive has long been related to low-cost tooling and a way to reduce the weight of a part. These criteria are still predominant but in addition, GWP of the materials, as well as recycled content and recyclability of the materials are rapidly gaining interest with a target to accompany the change from a linear economy to a circular economy. Composites are mainly known as materials than can be lightweight but that are difficult to recycle and integration of recycled materials in composites is not state of the art. FORVIA Faurecia is working on new thermoplastic composites that are manufactured from up to 100% of recycled thermoplastics. METHODOLOGY Faurecia together with a consortium around the IRT Jules Verne has developed a process to manufacture thermoplastic composite semi-pregs that has a high flexibility and enables the use of materials with low CO2 footprint. In particular, the thermoplastics that are used can be a postindustrial recycled material and even a postconsumer material. It is mixed with long chopped fibers or continuous woven fabrics to yield materials with properties similar to that of prime materials. RESULTS The conference will present the properties of the semi-pregs and some possible applications including seat structures, components of battery housings and even more structural body in white reinforcement applications. Current materials are based on recycled thermoplastics that are combined with prime continuous glass fibers. The performance of the materials is similar in terms of properties to that of prime materials and have a CO2 footprint between 1.5 and 2 kg CO2 eq/kg. The work that will be presented in this conference is related to a combination of recycled PET (coming from the packaging industry) and continuous woven glass fibers. LIMITATIONS OF THIS STUDY The presentation is presenting the results of a R&D project. The materials are not yet available industrially and are not yet applied in a production of a commercial car. What does the paper offer that is new in the filed of comparison to other works of the author? Previous work was on the development of thermoplastic composites and their application to different automotive parts. The topic of the recycled materials has not been presented CONCLUSION The material has a performance that can be in competition with aluminium and steel parts. It can have an advantage in terms of weight reduction, GWP, and can be a solution for ecodesign to reach a circular economy.



Dr.-Ing. Thierry RENAULT, Senior Expert Composites, Faurecia Lightweight Solutions

Continuous Fiber Thermoplastic Composites with High Recycled Content and Low Carbon Footprint

FWC2023-ASM-003 • Advanced & sustainable materials

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