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<p>This review systematically examines the manufacturing processes, application opportunities, substitution potential, and recycling strategies of carbon fiber-reinforced thermoplastic (CFRTP) composites. In the manufacturing sector, traditional molding techniques provide stability for mass production but are constrained by long cycle times and high tooling costs depending on the specific process, material system, and component geometry. In contrast, additive manufacturing enables tool-free fabrication of complex geometries; however, its mechanical properties are limited by porosity, anisotropy, incomplete impregnation, and insufficient interlayer adhesion. Emerging automated technologies, such as automated tape laying and laser-assisted in situ consolidation, are improving process efficiency and deposition control, although challenges remain in thermal management, consolidation quality, and defect detection. This review places particular emphasis on the existing applications of thermosetting composites, thereby establishing a context for the substitution and upgrading potential of CFRTPs. In the realm of recycling, an important strategy is to recover carbon fibers from thermoset CFRP waste and reuse them in secondary thermoplastic composite systems where appropriate. Current recycling methods—mechanical, chemical, and pyrolysis—each present distinct trade-offs: Mechanical approaches often compromise fiber length, architecture retention, and reinforcement efficiency; chemical recycling based on matrix degradation or dissolution faces challenges related to solvent or catalyst management, purification, secondary waste, and scalability, while pyrolysis can recover carbon fibers under suitable process conditions but requires careful control of temperature, atmosphere, char removal, and off-gas treatment. By integrating insights from materials science, advanced manufacturing, and sustainability assessment, this review establishes a foundational framework for evaluating the opportunities and limitations of CFRTPs in more sustainable composite manufacturing and recycling systems.</p>

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Review: manufacturing processes, application advances, and recycling transformation of carbon fiber-reinforced thermoplastic composites

  • 期刊论文

  • 发表日期：

    2026年7月26日

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  • Hailiang Su,
  • Mengfan Zhou,
  • Zhenxiao Wei,
  • Weilong Huang,
  • Min Liu

摘要

This review systematically examines the manufacturing processes, application opportunities, substitution potential, and recycling strategies of carbon fiber-reinforced thermoplastic (CFRTP) composites. In the manufacturing sector, traditional molding techniques provide stability for mass production but are constrained by long cycle times and high tooling costs depending on the specific process, material system, and component geometry. In contrast, additive manufacturing enables tool-free fabrication of complex geometries; however, its mechanical properties are limited by porosity, anisotropy, incomplete impregnation, and insufficient interlayer adhesion. Emerging automated technologies, such as automated tape laying and laser-assisted in situ consolidation, are improving process efficiency and deposition control, although challenges remain in thermal management, consolidation quality, and defect detection. This review places particular emphasis on the existing applications of thermosetting composites, thereby establishing a context for the substitution and upgrading potential of CFRTPs. In the realm of recycling, an important strategy is to recover carbon fibers from thermoset CFRP waste and reuse them in secondary thermoplastic composite systems where appropriate. Current recycling methods—mechanical, chemical, and pyrolysis—each present distinct trade-offs: Mechanical approaches often compromise fiber length, architecture retention, and reinforcement efficiency; chemical recycling based on matrix degradation or dissolution faces challenges related to solvent or catalyst management, purification, secondary waste, and scalability, while pyrolysis can recover carbon fibers under suitable process conditions but requires careful control of temperature, atmosphere, char removal, and off-gas treatment. By integrating insights from materials science, advanced manufacturing, and sustainability assessment, this review establishes a foundational framework for evaluating the opportunities and limitations of CFRTPs in more sustainable composite manufacturing and recycling systems.