Reuse of Uncured Carbon Fiber Prepreg Scrap via Calendering for Circular Composite Manufacturing

This technical study presents calendering as an innovative and continuous industrial solution for the reuse of uncured carbon fiber prepreg scraps, which are typically discarded in large quantities in the aerospace sector. By applying heat and pressure through rollers, the authors successfully transform residual fragments into functional sheets, promoting a circular economy that reduces environmental impact and raw material costs. Although the process induces a slight fiber misalignment, which decreases longitudinal strength, the results reveal significant improvements in transverse properties and increased material isotropy. Finally, the research validates the feasibility of this technique by fabricating a curved structural demonstrator, proving that these recycled composites maintain high stiffness and suitable thermal stability for secondary aeronautical applications.