What is currently emerging – pilot projects in Germany are making fibre-reinforced composites circular

Pilot projects are the bridge between an idea and industrial application. They demonstrate whether processes are robust enough, whether material qualities are consistently achieved, and whether supply and demand can be realistically brought together along the value chain. In fibre recycling, the scope of current research and development projects ranges from new pyrolysis approaches to strategies that keep components usable for longer, delaying the need for recycling. The following examples provide an insight into where this transfer is also being advanced outside of the WIRreFa project.

Laser-assisted “peeling” recycling for continuous carbon fibres (Fraunhofer EMI)

At Fraunhofer EMI, a process was presented in which carbon fibres are locally stripped of the matrix from thermoset composites using high-power lasers, while the fibre roving is simultaneously unwound. The aim is to preserve the quality of the fibres significantly better compared to conventional shredding. The approach specifically targets wound structures, such as hydrogen pressure vessels, thereby addressing a growing waste stream of the energy transition [1].

RE_SORT: Pyrolysis of thick-walled rotor blade composites (Fraunhofer WKI)

Thick-walled laminate areas represent a particular challenge for rotor blades. This is exactly where RE_SORT comes in: pyrolytic process routes are being investigated to recover fibres as well as oil and gas fractions and subsequently make them usable again. The balance between energy input, process stability, and the quality of the recovered fibres is crucial so that “disposal” becomes a raw material once more [2, 3, 4].

BladeReUse: Rotor blades as a component resource for infrastructure (Karlsruhe Institute of Technology)

Not every composite component needs to be recycled immediately. BladeReUse develops processes to reuse rotor blade segments in a resource-efficient manner, for example, for infrastructure applications such as noise protection, shoring, or coastal and water protection. To this end, disassembly, forming, and qualification issues as well as licensing requirements are being investigated. The approach shifts the focus from “recovering fibres” to “preserving component value” and can thus save time and emissions before recycling eventually takes place [5, 6].

ReusaBlade: Rotor blades for a second use (Fraunhofer IWES)

The ReusaBlade project focuses on the question of how decommissioned rotor blades can not only be recycled but also opened up as components or material sources for further use. For this purpose, criteria and processes are being developed that enable safe assessment, processing, and reuse. This approach pushes back the end-of-life and deploys recycling paths more specifically where they are actually needed [4, 7].

EoLO-HUBs: Process chain from rotor blade end-of-life to demonstration (Fraunhofer IWES)

In the European joint project EoLO-HUBs, the entire value chain is covered: from disassembly and pre-treatment to the recovery of fibres (including pyrolysis/solvolysis) and the processing of fibres for new applications. The goal is to present the processes in demonstration environments, including industrial-scale steps that today often still fail due to logistics, energy requirements, or a lack of quality standards [4, 8].

As of 2026-01-12

List of references
[1] Fraunhofer-Gesellschaft (2025). Innovative Recycling Method for Carbon Fiber. https://www.fraunhofer.de/en/press/research-news/2025/april-2025/innovative-recycling-method-for-carbon-fiber.html
[2] Fraunhofer IWES. RE SORT: Pyrolysis of thick-walled fiber composites as a key innovation in the recycling process for wind turbine rotor blades. https://www.iwes.fraunhofer.de/en/research-projects/current-projects/re-sort.html
[3] Fraunhofer WKI. RE_SORT: Sustainable and economic recycling of wind turbine rotor blades using pyrolysis of fiber composites. https://www.wki.fraunhofer.de/en/research-projects/2023/re-sort-wind-turbine-recycling-using-pyrolysis-of-fiber-composites.html
[4] Ludwig, N. (2025). Complex but dissolvable? Research projects on recycling rotor blades at Fraunhofer IWES. https://websites.fraunhofer.de/iwes-blog/en/complex-but-dissolvable-research-projects-on-recycling-rotor-blades-at-fraunhofer-iwes/niels-ludwig
[5] baunetzwerk.biz. (2025). Neue Wege beim GFK-Recycling. https://www.baunetzwerk.biz/neue-wege-beim-gfk-recycling
[6] KIT Stahl- und Leichtbau. Entwicklung einer Methode zur ressourceneinsparenden und CO2-reduzierenden Weiterverwendung von Rotorblättern im Infrastrukturbereich (BladeReUse). https://stahl.vaka.kit.edu/forschung_2004.php
[7] Fraunhofer IWES. ReusaBlade: Recyclable materials for rotor blades and their recycling. https://www.iwes.fraunhofer.de/en/research-projects/current-projects/reusablade.html
[8] Fraunhofer IWES. EoLO-HUBs: Wind turbine blades End of Life through Open HUBs for circular materials insustainable business models. https://www.iwes.fraunhofer.de/en/research-projects/current-projects/eolo-hubs.html