Researchers from the Swiss Federal Laboratories for Materials Science and Technology (Empa) and the chemical company Elantas have developed a new recyclable epoxy resin composite. This material is designed to replace traditional thermoset plastics in aircraft and train cabins, which are typically difficult to recycle and often end up in landfills or incinerators.
The innovation involves a phosphorus-based additive integrated into the epoxy resin. This additive provides flame retardant properties while allowing the material to soften and separate under specific conditions involving solvents and moderate heat. This process enables the recovery of high-value components, such as aramid honeycomb cores and glass or carbon fiber layers.
The project, supported by the Swiss Innovation Agency, confirmed that the new composite meets existing fire safety standards while maintaining mechanical performance comparable to conventional materials. Researchers are now working with Elantas to scale the production and recycling processes for commercial use in aviation, rail, energy infrastructure, and construction.
While the current focus is on recovering structural components, the team is also investigating potential methods to recycle the separated epoxy resin itself. This development aims to transition the industry from a linear model of manufacturing and disposal toward a circular economy, balancing lightweight requirements with sustainability goals.