A European research consortium, Carbowave, is advancing a breakthrough in carbon fiber manufacturing that promises to cut energy consumption, shorten production times, and reduce costs. Led in part by the German Institutes of Textile and Fiber Research (DITF), the project uses microwave and plasma heating to replace conventional energy-intensive stabilization and carbonization processes.

Traditional carbon fiber production from petroleum-based polyacrylonitrile (PAN) demands prolonged high-temperature furnace treatment, consuming vast amounts of energy while delivering low material yields. Carbowave s innovative method applies localized microwave and plasma energy directly to fibers, minimizing heat loss and accelerating processing.

The consortium s goals include developing PAN coatings to improve microwave absorption, creating plasma-based oxidative stabilization systems, and refining continuous-process technology. DITF is spearheading the integration of these processes into pilot-scale continuous production, with a special focus on plasma-assisted stabilization.

In addition to production efficiency, Carbowave addresses sustainability by enabling microwave-assisted decomposition of carbon fiber reinforced plastics (CFRP) for recycling, supporting a circular economy approach.

By combining faster, more efficient manufacturing with end-of-life recycling, Carbowave aims to make high-strength, lightweight carbon fiber composites more accessible for industries such as aerospace, automotive, and renewable energy.

Source: www.ditf.de