Cygnet Texkimp and Viritech have achieved a major milestone in the development of circular composite technologies by successfully recovering high-value continuous carbon fibers from hydrogen pressure vessels. The achievement is part of the Ford-led FCVGen2.0 program, a UK government-backed initiative aimed at accelerating the development of hydrogen fuel cell technologies for commercial vehicles. 

Funded in part by the Advanced Propulsion Centre UK (APC), the FCVGen2.0 consortium was created to design, build, and trial a fleet of hydrogen-powered Ford E-Transits. A core objective of the program is to explore end-of-life strategies for hydrogen storage components, including the recovery and reuse of carbon fiber from Type V pressure vessels. 

Working in partnership, composites equipment manufacturer Cygnet Texkimp and hydrogen powertrain innovator Viritech demonstrated a breakthrough in recycling composite tanks. Using Cygnet Texkimp’s Fibre Recovery System, the project recovered continuous carbon fibers from a novel nano-infused resin system developed by Viritech. The system applies superheated, cyclic steam through the proprietary DEECOM® process to remove the polymer matrix while preserving the structural integrity of the fibers. 

Unlike conventional recycling methods, which typically yield short, chopped fibers suitable only for low-performance applications, this approach enables the recovery of long, continuous fibers. These fibers were rewound onto bobbins and are now viable for reuse in advanced manufacturing processes such as filament winding, pultrusion, UD prepreg, and weaving—allowing them to directly replace virgin fibers in many structural components.

 “This is a significant step forward for the hydrogen vehicle supply chain,” said Dr Yan Liu, Senior R&D Specialist at Cygnet Texkimp. “Our Fibre Recovery System allows for Design for Recycling to become a practical reality—recovering valuable carbon fibers in a reusable form and reducing the environmental footprint of composite parts.” 

Simon Willis, Chief Technology Officer at Viritech, added: “Our collaboration with Cygnet Texkimp has yielded essential insights that feed directly into the design fundamentals of our pressure vessels. This enables us to ensure they are constructed with end-of-life recycling in mind.”

The partnership is also focused on evolving the associated manufacturing processes, specifically filament winding, to further enhance efficiency and sustainability. Cygnet Texkimp’s five-axis automated winding cell is being used alongside Viritech’s composite systems to optimize tank production and recycling workflows. 

Aislinn Kiely, Project Delivery Lead at the Advanced Propulsion Centre UK, commented: “The progress made by Cygnet Texkimp and Viritech underscores the importance of collaborative R&D in building a sustainable, zero-emission vehicle supply chain. Their work represents a meaningful contribution to the UK’s net-zero ambitions.” 

Source: cygnet-texkimp.com