Recycled Carbon Fiber Nonwoven Fabric

What is Carbon Fiber Nonwoven Fabric?

Carbon fiber nonwoven fabric is a sheet material made from carbon fibers using nonwoven processing methods. Unlike woven textiles, nonwoven fabrics are produced without spinning or weaving—instead, fibers are arranged randomly or directionally and bonded together through mechanical needling, heat pressing, or chemical adhesives. 

This structure results in a lightweight, strong, heat-resistant, and electrically conductive fabric ideal for a wide range of high-performance applications.

What is Recycled Carbon Fiber Nonwoven Fabric?

Recycled carbon fiber nonwoven fabric is made from reclaimed carbon fibers, processed using Thermolysis Co., Ltd.’s proprietary dry-laid needle-punching technology. We use clean, residue-free recycled carbon fibers sourced from tow waste, trimming scraps, expired prepregs, and decommissioned composites.

This product is available in 100% recycled form or blended with thermoplastics such as PET, PA6, and TPU to suit various application needs. The typical basis weight ranges from 100–400 g/m², with a standard product weight of 130 g/m². Custom formulations with chemical fiber blends can be produced based on specific downstream application requirements, including thermoplastic sheets and prepregs for composite uses.

Key Features

1.100% Recycled Carbon Fiber
Made entirely from recycled carbon fiber sourced from production waste, expired prepregs, and end-of-life composites—helping reduce carbon emissions and resource consumption.

2.Needle-Punch Technology
Mechanically interlocks fibers using barbed needles without adhesives, creating strong, flexible, and uniform fabrics suitable for complex surfaces. Maintains material purity and lightweight properties.

3.Flexible & Formable
More pliable than woven fabrics, with excellent drape and stretch across both X and Y axes—ideal for curved or contoured surfaces. 

4.Quasi-Isotropic Structure
Unlike woven fabrics with directional strength, nonwoven fabric offers multi-directional fiber distribution, including Z-axis reinforcement—resulting in balanced mechanical properties across 3D geometries.

5.Simplified Processing
Can be hot-pressed with thermoplastics to form stable polymer composites without the need for additional resin impregnation, reducing carbon footprint and improving production efficiency.

6.Smooth Surface Finish
Uniform fiber distribution with no visible weave, reducing the risk of pinholes or surface marks. Minimizes the need for fillers or coatings, saving time and cost.

7.Customizable Formulations
Fiber content can be adjusted from 10% to 100% RCF, and blended with polymers such as PET, PA6, or TPU to meet specific application demands.

8.Stable Weight & Thickness
Available basis weights range from 120–250 g/m², with consistent thickness and quality for reliable downstream processing.

9.Multi-Use Applications
Suitable for thermoplastic compression molding, structural reinforcement, EMI shielding, and more.

10.Eco-Friendly & ESG Aligned
A sustainable material that helps brands achieve ESG goals and promote a green image.
 

Main Applications

• Composite Reinforcement
  • Improves strength and impact resistance in automotive parts, aerospace components, and sporting goods.
• Lightweight Structural Materials
  • Used in vehicle bodies, aerospace interiors, and lightweight paneling for fuel efficiency and structural integrity.
• Conductive & Anti-Static Materials
  • Provides EMI shielding and static protection in electronic packaging and devices.
• Filtration Media
  • Ideal for air and water filtration systems with strong chemical resistance and breathability.
• Gas Diffusion Layers for Fuel Cells
  • Ensures excellent conductivity and gas permeability to enhance fuel cell performance.
• High-Temperature Insulation
  • Used in thermal insulation materials like furnace linings and fire-resistant fabrics.
• Other High-Performance Uses
  • Including wind turbine blades, golf clubs, bicycle frames, and medical equipment.  

Product Specifications

Note: All data based on internal analysis. Actual values may vary depending on production conditions.