Wholly Sustainable, Cost-Effective Carbon Fiber-Nylon Compounds

Carbon fiber composites have attracted considerable attention due to the potential for substantial mass savings, with many examples now implemented in the low volume luxury car market. However, migration to higher volume applications has been hindered by: (a) high material cost, (b) high processing times, and (c) perception of low sustainability. This project will address all three of these barriers: (a) carbon fiber material to replace aluminum in structural components at a cost penalty of no more than $5/Kg-saved (aka weight buy); (b) fitting into high-speed auto process, like injection molding; and (c) end-to-end sustainable material based on post-industrial waste carbon fiber and nylon 66, and the ability to recycle end-of-life auto parts. The opportunity lies in combining DowAksa USA LLC capabilities in carbon fiber manufacturing and resin chemistry intermediate production with the unique testing capabilities inherent within Pacific Northwest National Laboratory.