Composite materials are valued for their high stiffness, strength, and low density, offering durability, which makes them a popular choice in sustainable design. However, the complexity of recycling composites at the End-of-Life presents a challenge due to the combination of different materials. While bio-based composites, with lower CO2 emissions, offer a more sustainable alternative to fossil-based materials, the recycling problem remains an issue.

This thesis explores possible EoL options for biobased composites during the early stage of industrialisation to prevent future waste. The Material Driven Design method is used to explore the firstcycle flax/furan composite material. A recycling method, separating layers through intentional delamination, was identified, preserving the value of the fibres for reuse.

Research and tests have shown that the recycled material can be used in new products, and the potential of the recycled material was evaluated through a demonstration design. The project confirms that the life cycle of Eve-tiles can be extended in this way and provides valuable insights into the challenges and opportunities of sustainable composite materials.

This project addresses the growing environmental concern surrounding wind turbine blade waste by proposing an innovative solution for structural reuse. The primary focus is developing an adaptable assembly and connection system that effectively integrates retrieved segments into new structures. The approach involves segmentation and circular design principles, aiming to preserve the value and functionality of decommissioned wind turbine blades. This report provides a comprehensive overview of the problem context, research findings, and the ongoing development and design of the assembly and connection system. The report concludes with a design proposition for a scalable geodesic dome

The current vision of Microcab is to increase the repair capabilities of the VIANOVA. Part of that vision is to begin the shift towards a circular economy in which the lifecycle of the product is extended, and parts can be processed in a circular manner during the lifecycle. Considering that Microcab is a small company and the challenge is considerable, additional safety regulations mean that a vehicle should become a road-safe vehicle. This graduation project contributes to this challenge by researching the main question that focusses on the front section of the vehicle: ‘How can Microcab design the front section of the VIANOVA to increase the repairability and solve the safety issues?’. Through several analyses and explorative design directions, the result is a concept that reconfigures the front section of the VIANOVA to allow for increased repairability and better safety requirements while maintaining the goal of becoming more circular. An important requirement is that the concept should allow for a production volume of 500 units annually. The current design of the front clip is a single large body panel hand-made from a glass fibre reinforced thermoset, which is difficult to repurpose and recycle. Based on research data, a sustainable alternative known as thermoplastic olefin (TPO) is introduced. Furthermore, the front clip has been split into four segments. These changes allow for better repair capabilities and lower the overall impact of a low-speed collision. In order to make this possible, structures were required to support the panels and increase energy absorption. The bonnet with incorporated headlights is enlarged to increase accessibility during service and fixated on the support structure, removing it from the impact zone. The support was required to improve safety for pedestrians and increase protection of internal components. This support consists of adding an energy absorber, upper load beams, cross member, and extending the width of the bumper beam. Additionally, it is recommended to use plastic fasteners to increase circular capabilities, considering that these are more likely to break, allowing for the body panels to remain intact. Lastly, it is recommended to implement a different type of surface finish. 3M provides an PVC-free wrap material, reducing the use of harmful chemicals and increasing repairability and circularity. This change also provides opportunities to illustrate internals or implement advertisement. Therefore, the project reveals that there are multiple elements that can have a positive influence on the repairability and safety issues while at the same time, shift towards a circular economy. The recommendations that emerged from the project provide a high desirability, but will require follow-up research am physical crash testing to determine optimal configuration of the front section, and create a better understanding of the elements and how they influence impact resistance and repairability.

In this report, an overview of the most common recycling methods for composite materials is created. It describes the process and recyclate characteristics, as well as the (dis)advantages of each method and the environmental and technological development. To draw conclusions on the current feasibility of composite recycling, the gathered data is analysed on the subject of application, quality, economy and sustainability. The report ends with a future outlook, and what implications this might have.

The wind energy industry is growing significantly, which increases the number of decommissioned wind turbines as well. The blades of wind turbines are mainly made of fiber reinforced thermoset polymer composite, which is difficult to recycle. Most blades currently end up in landfill or incineration which is a waste of this high value material. In this project, a valuable application for mechanically recycled composite material is designed, which will ensure the wind turbine blades of an end-of-life situation that fits within the circular economy. Material research is executed to get a grip on the characteristics of the shredded composite. These specific characteristics are eventually used to generate ideas on valuable applications for the material in which the recyclate is a wanted addition, instead of a disturbance. Based on the formulated vision, requirements and wishes, an electrical car charger is selected as the best suitable idea. This product demonstrates how the shreds can be reused in a thermoplastic material. It has a symbolic link with the wind energy industry and anticipates on the energy suppliers, who own the wind turbines, by recycling the material into a product they offer.
The electrical charger is produced by pressing the shredded composite between two sheets of thermoplastic material and shaping this with vacuum forming. After its use, the product can be again recycled into new applications. However, the shredded composite will be part of a cascading model in which the fiber size will decrease with every recycling procedure. The design is only reusing a small amount of the total supply of composite waste and is therefore not an all-encompassing solution to the problem. Additionally, mechanical recycling does cause significant down-cycling of the high value material. Therefore, it is best to replace the thermoset polymer composites with a better recyclable material, until a recycling procedure turning the fibers and resin back into raw materials is fully developed.