Thermoforming Process Effect on Performances of Thermoplastic/Recycled Carbon Fiber Composites

The reuse of recycled carbon fibers (rCF) is a response to growing environmental concerns associated with the composites industry. Recycling and reusing carbon fibers represents a more sustainable alternative by reducing waste at the end of the life cycle of composite materials and decreasing dependency on virgin raw materials. This study investigates the influence of process parameters on two different non-woven mats made by carding rCF and blending with thermoplastic filaments: Carbiso TM-PA6/60 and TM-MAPP/60. Two processing methods were examined—one-shot process (M1) and lamination (M2)—to fabricate multilayer coupons. The results indicate that the two-layer panels produced using M2 exhibited a lower porosity (9.9% for PA6/60 and 4.1 for MAPP/60) and superior mechanical performance. However, the differences in performance between the two methods diminished as the number of layers increased. Concerning matrix–fiber compatibility, MAPP/60 showed the best results due to the fiber’s roughness, matrix particles on the fibers, and the incorporation of maleic anhydride in polypropylene (PP), significantly enhancing adhesion.