Recyclability of Composites in Commercial Aviation: Industrial Specificities, Readiness and Challenges

The integration of composite materials into commercial aviation has transformed the industry by providing superior performance benefits, including enhanced fuel efficiency, reduced emissions, and improved structural integrity. With a significant shift towards aircraft featuring high contents of composite materials, the focus has also turned to the challenges associated with the end-of-life management of these materials. Unlike metals, composites are notoriously difficult to recycle due to the strong bonding between fibres and resin, creating significant environmental and economic challenges. The methodology employed—consisting of an extensive literature review that prioritises a holistic approach—aims to provide an overview of the status of composite recyclability in aviation. With this, the report investigates the durability of composites under operational conditions, the associated environmental factors, and their impact on the recycling potential. The dismantling processes for decommissioned aircraft are analysed to identify strategies that preserve material integrity for effective recycling. Established recycling methods are critically evaluated alongside innovative approaches. The study highlights the limitations of current techniques in terms of costs, energy consumption, and material degradation while exploring emerging technologies that aim to overcome these barriers. It is concluded that currently available techniques do not possess the industrial maturity required to handle the amount of composite materials being employed in aviation. Moreover, there is a clear discontinuity between the developments in the usage of composites and their end-of-life recycling, which can cause serious environmental and economic challenges in future years. By combining information regarding composite usage and aircraft retirements, assessing the environmental and economic implications of composite recycling as well as available techniques, and proposing pathways for improvement, this research underscores the importance of adopting sustainable practices in aviation. The findings aim to contribute to the development of a circular economy within the aerospace sector, ensuring the long-term viability and environmental responsibility of future composite-intensive aircraft designs. This is performed by calling for a multi-stakeholder strategy to drive recycling readiness and facilitate the evolution towards a circular economy in aviation, leading to more sustainable design, production, and dismantlement of aircraft in the future.