Technology: automotive, new smart & green fabrics from recycled carbon fibre

The innovative project was born from the idea of ​​integrating electronics into fabrics TEX-STYLE.

Innovating car interior trim thanks to the use of hi-tech fabrics made from carbon fiber waste. 

Target

Thanks to an innovative production process, developed by ENEA and its partners, it is possible to produce an electrically conductive yarn.

“We have developed an innovative process that allows us to produce an electrically conductive yarn based on carbon fiber waste, capable of being integrated into fabrics and electronic circuits to exploit their electrical conduction capabilities,” explains Flavio Caretto, researcher at the ENEA laboratory of functional materials and technologies for sustainable applications and project manager for the Agency.

Applications

Thanks to the hi-tech yarn, developed in the laboratories of the ENEA Research Center in Brindisi in collaboration with the University of Bergamo, it will be possible to create, for example, a heating system integrated into the internal coverings of seats and armrests or integrated wiring with external electronics to perform certain functions, such as turning on the lights inside the car.

To produce this type of yarn, the team of researchers had to re-adapt one of the traditional spinning processes and adapt it to waste carbon fibre, mainly coming from the industrial and aeronautical sectors (over 50% of a Boeing 878 aircraft is made of carbon fibre. ).

Usage forecasts

“Due to its extraordinary properties of resistance and lightness, the demand for this fiber has grown at exponential rates all over the world. Recent studies show that global demand for carbon fiber-based composite materials tripled from 2010 to 2020 and is expected to exceed 190 thousand tons by 2050. But use of this scale has led to – and will continue to do so – a production of enormous quantities of waste. This situation has encouraged us researchers and the industry itself to develop new technologies for the recycling of carbon fibres, as demonstrated by the project TEX-STYLE. With a double advantage in terms of economics and environmental impact because the incineration or landfill disposal of this precious material is avoided”, underlines Caretto.

In addition to the innovative spinning process, ENEA researchers tested yarns with different mixing percentages of carbon fibers and polyester to optimize electrical conductivity and workability.

Sectors Involved

In addition to the sector automotive, thanks to a total financing of around 10 million euros, the other partners of the project TEX-STYLE they are studying new intelligent and multifunctional fabrics, based on natural, bioderived and recycled fibres, to be used for the production of technical fabrics, fashion and furnishings. Starting from the combination of sustainable and intelligent materials, in fact, TEX-STYLE will pave the way for the design of high quality, low environmental impact creative products, with a distinctive Made in Italy label.

TEX-STYLE project partnership

• The supply chain concept involves the participation of research institutions
  • University of Cagliari and Bologna
  • ENEA
  • CRdC New Technologies for Production Activities Scarl,
• all stages of the value chain are covered and range from
  • design
    • Dreamlux,
    • FCA Style Center,
    • Let's – Webearable Solutions Srl
  • materials
    • Irplast,
    • Technova,
  • production of smart fabrics
    • Let's – Webearable Solutions Srl,
    • Dreamlux,
    • Apollo
• end users for different applications
  • CRF/FCA,
  • Let's – Webearable Solutions Srl, Dreamlux,
• supported by national sector associations in the fashion and furniture sector
  • Cosmob,
  • Next.

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