Daher introduced its fully industrialized thermoplastic composite upcycling chain at JEC World 2026, enabling the conversion of scrap and end-of-life aerostructures into carbon-PPS pellets and additive manufacturing filaments. The demonstration, held from March 10 to 12 in Paris, featured carbon-PPS pellets produced from manufacturing scrap, a filament suitable for 3D printing technical parts, and an example of a part fabricated from this filament. This process advances sustainable manufacturing and promotes material circularity for the aerospace and automotive sectors.
Background
For over a decade, Daher has developed thermoplastic composite technologies to address aerospace industry requirements, such as lightweighting, higher production rates, and reduced carbon emissions.For more than 10 years, Daher has been investing in mastering thermoplastic composites for aeronautical programs{{cite:}} At JEC World 2026, the company presented the complete value chain-from collecting production scrap to transforming it into semi-finished carbon-PPS pellets suitable for industrial applications.Daher presented a structured process from scrap collection, grinding at Shap'in, to pellets containing 56 % carbon fiber, suitable for injection molding{{cite:}}
Details
Daher's upcycling process converts 100% of pure carbon-PPS scrap generated at its facilities into pellets with 56% carbon fiber content. These pellets offer high resistance to temperature, moisture, and chemicals, with mechanical properties appropriate for injection molding of intricate technical components.100 % of pure carbon PPS scrap is upcycled into pellets with 56 % carbon fiber, offering high mechanical and environmental resistance{{cite:}} The process yields an estimated four to eight metric tons annually, with 1.5 metric tons currently available for sale.Production capacity is estimated at four to eight metric tons per year; 1.5 metric tons are available for sale{{cite:}}
Daher also developed an additive manufacturing filament from recycled material and displayed a corresponding printed part at its exhibit.Daher developed a filament for additive manufacturing from the recycled PPS material; a printed part was on display{{cite:}}
For end-of-life composites, Daher collaborated with Airbus, Toray Advanced Composites, and Tarmac Aerosave to process thermoplastic panels from retired A380 aircraft into components for A320neo production. This initiative received the JEC Innovation Award in the Circularity & Recycling category.The project recycled A380 thermoplastic panels into new A320neo parts and won the JEC Innovation Award for Circularity & Recycling{{cite:}}{{cite:}}
Outlook
Daher's industrial-scale upcycling chain establishes a model for incorporating recycled thermoplastic composites into aerospace and adjacent industries. The next stage includes implementing the available 1.5 metric tons in customer applications across multiple sectors. This approach presents opportunities for expansion into automotive additive manufacturing and broader technical molding markets.
