The EuReComp demonstrators showcase how circular economy principles can be applied to composite materials. Using recycled and reused fibres recovered from end-of-life (EoL) composite components, the project developed a series of real industrial applications across the automotive, renewable energy and construction sectors.
These demonstrators validate the technical feasibility, performance and sustainability potential of circular composite solutions.
Automotive Demonstrators
Steering Wheel: Additive Manufacturing with Recycled Carbon Fibres
This demonstrator presents a 3D-printed automotive steering wheel manufactured using recycled carbon-fibre reinforced polyamide (PA6/66-rCF). Advanced design-for-additive-manufacturing strategies and optimized printing orientation enabled the production of a fully solid component with excellent surface quality and structural integrity.
The successful demonstration shows that recycled composite materials can be used in high-performance automotive applications, combining lightweight design, sustainability and advanced manufacturing technologies.
Key Highlights
- • Manufactured using 100% recycled carbon fibre reinforced filament
- • Optimized 45° printing orientations to reduce warping
- • Enhanced geometry for improved stress distribution
Steering Shaft: Structural Component with Recycled Fibres
The automotive shaft demonstrator illustrates how recycled composite fibres can be applied in structural, load-bearing components. Manufactured using filament winding techniques, the shaft demonstrates high strength and precision while integrating recycled materials recovered through advanced recycling processes.
This application validates the potential of circular composites for mechanically demanding automotive components, supporting the transition toward more sustainable manufacturing practices.
Key Highlights
- • Structural component designed for high mechanical loads
- • Manufactured using filament winding technology
- • Utilizes recycled carbon fibres
Racing Seat: Circular Composite Solution
The racing seat demonstrator represents a fully circular composite component, manufactured entirely using recycled carbon fibre materials. Continuous fibres recovered through solvolysis recycling were reprocessed into prepregs and used to produce the main seat structure.
To enhance structural performance, reinforced thermoplastic inserts made from recycled chopped fibres were integrated into highly loaded areas. The final design demonstrates that recycled composite materials can achieve performance levels close to virgin materials, making them suitable for demanding motor-sport applications.
Key Highlights
- • Manufactured using recycled continuous carbon fibres
- • Solvolysis recycling and surface re-treatment for fibre recovery
- • Structural reinforcement using recycled fibre thermoplastic inserts
Floating Photovoltaic System
Repurposing Wind Turbine Blades for Renewable Energy Infrastructure
This demonstrator explores a novel approach for managing end-of-life (EoL) wind turbine blades by repurposing them into structural elements for a floating photovoltaic (PV) platform.
Sections of wind turbine blades are transformed into durable floating structures capable of supporting photovoltaic modules on water surfaces. This concept extends the lifecycle of composite materials while contributing to renewable energy generation.
Key Highlights
- • Repurposing wind turbine blade components
- • Structural floats for floating PV systems
- • Demonstrates large-scale reuse of composite structures
ROCCA Demonstrator
Mobile Cabin Built with Recycled and Reused Composites
The ROCCA 5-walls cabin is a multifunctional mobile structure built using recycled and reused composite materials recovered from different industrial sectors. Components such as wind turbine blade sections, composite sandwich panels and modified aviation pressure tanks were integrated into the structure.
With approximately 676 kg of reused composite materials, the cabin demonstrates how large composite parts can be transformed into durable and functional infrastructure solutions. The modular design allows the structure to be easily assembled, dismantled and relocated.
Key Highlights
- • Built using recycled and reused composite materials
- • Integrates components from wind turbine blades and aviation structures
- • Modular and easily relocatable design
Training for Circular Composite Management
Life-Long Learning Programme for End-of-Life Composite Management
To support the transition toward a circular economy for composite materials, the EuReComp developed a Life-Long Learning Programme focused on End-of-Life (EoL) composite management. The course provides structured training on the processes, technologies and strategies required for the sustainable handling, reuse and recycling of composite materials.
The programme brings together the knowledge generated throughout the project and translates it into an accessible online learning course designed for students, engineers, researchers and industry professionals working with composite materials.
Course Structure
The training programme consists of eight learning modules, covering the complete lifecycle of composite materials:
- • Overview of composite circularity concepts
- • Inspection of composite structures
- • Dismantling and sorting procedures
- • Repair techniques for composite components
- • Reuse strategies
- • Recycling technologies for fibre-reinforced composites
- • Composite manufacturing technologies
- • Safety and environmental performance
Each module includes visual presentations, narrated explanations and educational videos, allowing learners to explore complex technical concepts through an interactive and accessible format.
Accessible Online Learning
The course is hosted on the Helios e-learning platform of the National Technical University of Athens and remains openly accessible beyond the project’s lifetime.
This ensures the long-term availability of EuReComp knowledge, supporting professionals, researchers and students interested in circular solutions for composite materials.
Course access: https://helios.ntua.gr/course/section.php?id=21601
The training material will also be made available through the Center for Lifelong Learning NTUA, further expanding its reach to the broader education and professional community.