{"id":37640,"date":"2026-09-02T09:01:46","date_gmt":"2026-09-02T07:01:46","guid":{"rendered":"https:\/\/innovationspark-ost.ch\/recyclable-composite-material-makes-airplanes-and-trains-recyclable\/"},"modified":"2026-09-02T09:03:27","modified_gmt":"2026-09-02T07:03:27","slug":"recyclable-composite-material-makes-airplanes-and-trains-recyclable","status":"publish","type":"post","link":"https:\/\/innovationspark-ost.ch\/en\/recyclable-composite-material-makes-airplanes-and-trains-recyclable\/","title":{"rendered":"Recyclable composite material makes airplanes and trains recyclable"},"content":{"rendered":"\t\t
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Airplanes and passenger trains must meet strict safety requirements, including those related to fire protection. This calls for materials that are flame-retardant, lightweight, robust, and scalable. Working with their industry partner Elantas, Empa researchers have now succeeded for the first time in making such a material\u2014a composite\u2014fully recyclable. <\/h4>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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\u201cNo flying machine will ever fly from New York to Paris,\u201d aviation pioneer Orville Wright once said. What even the visionary Wright brothers considered impossible is now a reality\u2014thanks, in part, to new materials that make modern aircraft and engines possible in the first place. In the more than 100 years since the Wrights\u2019 first flight attempts, aviation has not only become more powerful but, fortunately, also significantly safer. The materials used in aircraft construction must meet the strictest safety requirements, including fire safety standards. At the same time, they must be lightweight and mechanically robust\u2014and, increasingly, recyclable as well. <\/p>

\u201cBringing all these properties together under one roof is a challenge,\u201d explains Empa researcher Sabyasachi Gaan from the \u201cAdvanced Fibers\u201d laboratory. \u201cFor example, when you make a material flame-retardant, you always end up altering its other properties as well.\u201d Gaan and his team, together with their industry partner Elantas\u2014part of the German specialty chemicals group ALTANA\u2014took on this challenge in a project supported by Innosuisse. Their focus was on a specific composite material used in the interior construction of airplanes and trains, such as for the floor of the passenger cabin. <\/p><\/div><\/div>

Epoxy Is Becoming More Sustainable<\/h5>
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Recyclable: With the right solvent and a little heat, the \u201csandwich\u201d can be broken down into its individual components. Image: Empa <\/div><\/div><\/div>

The material is a multilayer \u201csandwich.\u201d At its center is a honeycomb structure made of aramid, a heat-resistant plastic. This sturdy, lightweight core is covered on top and bottom with several flat-woven layers of glass or carbon fibers. Epoxy resin serves as the binder, as it does in many composite materials. Normally, this polymer cannot be recycled either chemically or thermally\u2014in other words, it can neither be melted down nor dissolved. \u201cComposites containing epoxy currently end up in landfills or are incinerated,\u201d says Gaan. <\/p>

This is exactly where the Empa researchers have an ace up their sleeve. They have developed an additive for epoxy resin that makes the material flame-retardant\u2014and recyclable at the same time. If this phosphorus-containing molecule is added to the epoxy during production, the material can be softened and reshaped under certain conditions after it has cured\u2014a process known as thermomechanical recycling, which was previously impossible for epoxy. <\/p><\/div><\/div>

All components recovered<\/h5>

In the Innosuisse project, however, the partners pursued a different goal: the complete recycling of the composite material. With the right solvent and a little heat, the \u201csandwich\u201d can be broken down again into its individual components: the honeycomb structure and the woven fibers. Aramid honeycombs in particular\u2014but also carbon fibers\u2014are relatively expensive. Recycling them is therefore also economically attractive. \u201cIn principle, it\u2019s also possible to recover the epoxy resin itself from the solution. We plan to tackle that in future projects,\u201d says Gaan. <\/p>

The recyclable epoxy resin was developed at Empa. Working with Elantas, the researchers have now explored its potential for industrial application for the first time. \u201cOur material complies with fire safety regulations and achieves nearly the same beneficial mechanical properties as conventional epoxy,\u201d says Gaan. \u201cBut for the first time, it allows for the complete recycling of the composite material.\u201d <\/p>

The project partners are satisfied with how the project is progressing. The next step is to further scale up production and recycling. \u201cFor the aerospace industry, it is crucial to combine fire protection, lightweight construction, and recyclability. This epoxy composite system demonstrates that this is now possible for the first time,\u201d says Fiorenzo Lenzi, Head of the Aerospace\/Ballistic Product Line at Elantas. <\/p>

At the same time, Sabyasachi Gaan and his team are already conducting research into further applications for the recyclable, flame-retardant plastic, such as in the energy sector and the construction industry. The scientist emphasizes that the fact a material has come this far is also thanks to basic research. \u201cBefore we can work on the applications, we need to have a very good understanding of the material\u2019s properties.\u201d The Wright brothers would likely agree with him. For, as Wilbur Wright wrote in a letter to engineer Octave Chanute in 1900, \u201cIt is possible to fly without engines, but not without knowledge and skill.\u201d <\/p><\/div><\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Innovations for Switzerland\u2014Thanks to New Materials<\/h5>

About 70% of all innovations are based on new materials. Outstanding materials research and technology development are therefore essential for an innovation hub like Switzerland. This is exactly what Empa, the materials research institute of the ETH Domain, has stood for\u2014for more than 120 years. Here, interdisciplinary teams are constantly creating new innovations, such as biodegradable batteries and computer components, drones that can dive into water while in flight, digital twins of entire cities, novel therapies against antibiotic-resistant pathogens, alternative materials for problematic substances like PFAS, and much more. Through countless industrial collaborations and spin-offs, Empa\u2019s vision\u2014\u201cMaterials and Technologies for a Sustainable Future\u201d\u2014is thus carried out into the Swiss economy and society. <\/p><\/div>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Go to Empa’s press release<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

Airplanes and passenger trains must meet strict safety requirements, including those related to fire protection. This calls for materials that are flame-retardant, lightweight, robust, and scalable. Working with their industry […]<\/p>\n","protected":false},"author":17,"featured_media":37638,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_price":"","_stock":"","_tribe_ticket_header":"","_tribe_default_ticket_provider":"","_ticket_start_date":"","_ticket_end_date":"","_tribe_ticket_show_description":"","_tribe_ticket_show_not_going":false,"_tribe_ticket_use_global_stock":"","_tribe_ticket_global_stock_level":"","_global_stock_mode":"","_global_stock_cap":"","_tribe_rsvp_for_event":"","_tribe_ticket_going_count":"","_tribe_ticket_not_going_count":"","_tribe_tickets_list":"[]","_tribe_ticket_has_attendee_info_fields":false,"footnotes":""},"categories":[109],"tags":[],"class_list":["post-37640","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-allgemein"],"acf":[],"yoast_head":"\nRecyclable composite material makes airplanes and trains recyclable - Switzerland Innovation Park Ost<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/innovationspark-ost.ch\/en\/recyclable-composite-material-makes-airplanes-and-trains-recyclable\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Recyclable composite material makes airplanes and trains recyclable\" \/>\n<meta property=\"og:description\" content=\"Airplanes and passenger trains must meet strict safety requirements, including those related to fire protection. 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