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J. Compos. Sci.
Volume 9
Issue 8
10.3390/jcs9080441
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement

by
Sara Taherinezhad Tayebi
1,2,
Tommaso Pini
1,2,*,
Bruno Caruso
1,
Matteo Sambucci
1,2,
Irene Bavasso
1,2,
Fabrizio Sarasini
1,2,
Jacopo Tirillò
1,2 and
Marco Valente
1,2
1
Department of Chemical Engineering Materials Environment, Sapienza University of Rome, 00184 Rome, Italy
2
INSTM Reference Laboratory for Engineering of Surface Treatments, UdR Rome, Sapienza University of Rome, 00184 Rome, Italy
*
Author to whom correspondence should be addressed.
J. Compos. Sci. 2025, 9(8), 441; https://doi.org/10.3390/jcs9080441 (registering DOI)
Submission received: 9 July 2025 / Revised: 13 August 2025 / Accepted: 15 August 2025 / Published: 17 August 2025
(This article belongs to the Special Issue Carbon Fiber Composites, 4th Edition)
Versions Notes

Abstract

Recently, environmental issues have compelled people worldwide to pursue sustainability and adopt circular economy practices across all engineering sectors, including polymer engineering and composite fabrication. A transition towards fabric-reinforced thermoplastics (FRTPs), a greener solution, has been recommended in recent years. On the other hand, utilizing recovered reinforcing phases, such as recycled carbon fiber (rCF), has attracted tremendous attention. In this framework, the aim of this research is to investigate the performance of acrylic-based FRTPs (Elium® resin developed by Arkema). Woven virgin carbon fiber (vCF) and non-woven recycled carbon fiber (rCF) fabrics were used as reinforcement architectures for the fabrication of composites via resin infusion. The optimized formulation selected for the matrix showed flexural modulus and flexural strength of 5 GPa and 78 MPa, respectively. Composites prepared with woven vCF reached 36 GPa and 620 MPa values of flexural modulus and strength, respectively. The study of non-woven fabric is of particular interest, because the web is composed of recycled carbon fibers obtained from end-of-life (EoL) thermoset composite components. The results were promising; the flexural modulus reached 8 GPa, and the flexural strength was 113 MPa. Improvements are anticipated, especially in the parameters and conditions of the molding process.
Keywords: sustainability; circular economy; thermoplastic composites; Elium® resin; non-woven fabrics; recycling; reactive processing sustainability; circular economy; thermoplastic composites; Elium® resin; non-woven fabrics; recycling; reactive processing

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MDPI and ACS Style

Taherinezhad Tayebi, S.; Pini, T.; Caruso, B.; Sambucci, M.; Bavasso, I.; Sarasini, F.; Tirillò, J.; Valente, M. Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement. J. Compos. Sci. 2025, 9, 441. https://doi.org/10.3390/jcs9080441

AMA Style

Taherinezhad Tayebi S, Pini T, Caruso B, Sambucci M, Bavasso I, Sarasini F, Tirillò J, Valente M. Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement. Journal of Composites Science. 2025; 9(8):441. https://doi.org/10.3390/jcs9080441

Chicago/Turabian Style

Taherinezhad Tayebi, Sara, Tommaso Pini, Bruno Caruso, Matteo Sambucci, Irene Bavasso, Fabrizio Sarasini, Jacopo Tirillò, and Marco Valente. 2025. "Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement" Journal of Composites Science 9, no. 8: 441. https://doi.org/10.3390/jcs9080441

APA Style

Taherinezhad Tayebi, S., Pini, T., Caruso, B., Sambucci, M., Bavasso, I., Sarasini, F., Tirillò, J., & Valente, M. (2025). Sustainable Acrylic Thermoplastic Composites via Vacuum-Assisted Resin Infusion Molding: Evaluation and Comparison of Fabrics and Recycled Non-Woven Carbon Fiber as Reinforcement. Journal of Composites Science, 9(8), 441. https://doi.org/10.3390/jcs9080441

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