Demanufacturing of thermoplastic composites: Small scale experiments exploring ply separation and recovery

Parsons, Andrew J.; Johnson, Michael S.; Piano, Samanta; De Focatiis, Davide S.A.

Abstract

Thermoplastic composites are intrinsically suited to recycling, but processes are poorly realised. Methods applied to thermosets are energy intensive, resulting in fibre downgrading and matrix loss. With digital manufacturing and data intertwining, the exact construction of a component can now be known. As such, instead of destructive recycling, a thermoplastic component might instead be demanufactured by peeling layers apart. In this study, the potential for recovering thermoplastic tapes by controlled peel was explored through novel small-scale tests. Unidirectional composites of three different tapes (PP/glass, PBT/glass and PA6/carbon) were compression moulded and subjected to transverse, lap shear and peel testing. Representative load and temperature conditions were established and their effects on the morphology of the recovered tape were considered. It was determined that peeling could be achieved well below the matrix melt temperature with only modest loading, and that contact failure changed from adhesive to cohesive at higher temperatures.

Citation

Parsons, A. J., Johnson, M. S., Piano, S., & De Focatiis, D. S. (2025). Demanufacturing of thermoplastic composites: Small scale experiments exploring ply separation and recovery. Composites Part A: Applied Science and Manufacturing, 190, Article 108626. https://doi.org/10.1016/j.compositesa.2024.108626

• Journal Article Type: Article
• Acceptance Date: Nov 26, 2024
• Online Publication Date: Nov 28, 2024
• Publication Date: Mar 1, 2025
• Deposit Date: Dec 2, 2024
• Publicly Available Date: Nov 29, 2025
• Journal: Composites Part A: Applied Science and Manufacturing
• Print ISSN: 1359-835X
• Electronic ISSN: 1878-5840
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 190
• Article Number: 108626
• DOI: https://doi.org/10.1016/j.compositesa.2024.108626
• Public URL: https://nottingham-repository.worktribe.com/output/42786344
• Publisher URL: https://www.sciencedirect.com/science/article/abs/pii/S1359835X24006249
• Additional Information: .