Toray Advanced Composites, Daher and TARMAC Aerosave have launched a joint recycling programme focused on end-of-life aerospace materials. The initiative, supported by Airbus, centres on the reuse of continuous fibre-reinforced thermoplastic composites from retired commercial aircraft.

The project aims to extend the life of these composite materials through remanufacturing processes and a closed-loop recycling system. Initial focus is on components from Airbus A380 aircraft, including over 10,000 flying parts made from carbon/PPS Toray Cetex TC1100 thermoplastic composite, specifically pylon covers.

Toray is monitoring the quality of reused materials. Daher is leading reshaping and quality checks. TARMAC is responsible for careful dismantling, ensuring structural integrity. Airbus is providing material reuse support.

Toray CEO Scott Unger says: “Thermoplastic materials offer great potential for recycling. Through this initiative, we aim to build on that strength by exploring new opportunities for recycling technology development — where our high-performance materials are not just recycled, but meaningfully reused and reintegrated into other structural aerospace applications.” He adds: “As demand for commercial aircraft continues to increase, it is critical we make progress on recyclability of thermoplastic and thermoset composite materials and reduce the impact of our industry on the environment.”

Daher’s R&D director Julie Vadour says: “For many years, Daher has relied on thermoplastic composites to develop structural parts for next-generation aircraft. These materials offer lightness, high production compatibility and – crucially – true sustainability. Beyond their weldability and reusability, we are actively advancing recycling processes for both end-of-life parts and manufacturing waste, particularly on our Nantes site.”

TARMAC Aerosave president Alexandre Brun says: “Sorting and recovering the materials that make up an aircraft is in the DNA of TARMAC Aerosave. We are constantly working to improve our recycling rate, which currently stands at 92%. This joint work on the re-use of thermoplastic composites contributes to our expertise in A380 recycling and our contribution to the eco-design of the new generation of aircraft.”