By: ICN Bureau
Last updated : November 04, 2025 11:04 am
Promoting application development from recycled carbon fiber nonwoven fabrics
Toray Industries announced the development of an advanced recycling technology capable of decomposing diverse carbon fiber reinforced plastics (CFRP) made from thermosetting resins while maintaining the strength and surface quality of the recovered fibers. Leveraging this breakthrough, Toray has successfully produced a nonwoven fabric using recycled carbon fibers.
The company has begun providing prototype samples to customers to support the development of performance and decorative materials across various sectors, including automotive, construction, electrical and electronics, and daily-use products. Toray will continue technical evaluations in collaboration with customers to meet specific industry needs.
CFRP is widely used in industries such as aviation and wind energy, where recycling has traditionally relied on chemical processes or high-temperature pyrolysis to recover fibers. However, these methods often result in thermal damage and residual resin, limiting the quality and applicability of the recycled material. Addressing these challenges, Toray utilized its deep expertise in organic synthesis and polymer polymerization to create a unique decomposition agent. This agent enables the breakdown of highly durable, three-dimensionally crosslinked thermosetting resins at lower temperatures than conventional methods.
Through this innovative process, Toray has achieved a recycling technology that allows carbon fibers to retain over 95 per cent of the tensile strength of virgin petroleum-derived fibers. Additionally, carbon dioxide emissions generated during recycling are estimated to be less than half those associated with virgin fiber production. The resulting recycled carbon fiber exhibits superior strength, minimal fiber breakage during post-processing, low resin residue, and exceptional surface quality—making it suitable for a wide range of applications.
Toray has also succeeded in processing these recycled fibers into sheet-form nonwoven fabrics. By controlling fiber dispersion in water, the company can produce both uniform nonwoven structures and distinctive textured designs reminiscent of washi (traditional Japanese paper). The resulting fabric combines carbon fiber’s inherent functionalities—such as radio frequency shielding and thermal conductivity—with a refined aesthetic appeal.
This innovative fabric is featured in the interior and exterior components of the concept car (vision model) that Mazda Motor Corporation is exhibiting at the Japan Mobility Show 2025, held at Tokyo Big Sight from October 30 to November 9.