Fairmat’s innovative recycling technology allows for the production of 100% recycled carbon composites that retain their strength and lightweight properties. By partnering with companies like Hexcel, Fairmat has established a 10-year agreement to recycle carbon fiber composite materials from Hexcel’s Salt Lake City facility for reuse in various commercial markets. Additionally, the partnership with Exel Composites focuses on recycling carbon fiber composite scrap from Exel’s plants in Finland, transforming it into high-performance CFRP chips using the proprietary cutting technologies described above.

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Fairmat has made significant strides in developing mechanical recycling processes. Established in 2020 by Benjamin Saada, Fairmat has collaborated with partners such as Hexcel, Dassault Aviation, Exel Composites and Tarmac Aerospace. These partnerships drive Fairmat’s mission of closing the loop on carbon fiber waste and making significant strides in sustainability.

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Thermal recycling known as pyrolysis: Thermal recycling uses high temperatures to decompose the resin matrix in carbon fiber composites, leaving behind clean fibers. While effective, this method requires significant energy input and may release harmful emissions if not properly managed.

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Chemical recycling known as solvolysis: Chemical recycling employs solvents to dissolve the resin matrix, separating the fibers without damaging their structure. This method is efficient and results in high-quality recycled fibers, although it involves complex chemical processes and significant chemical waste if not properly managed.

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In various high-performance sectors like wind energy, carbon fiber composites are indispensable due to their light weight and high-strength properties. However, the end-of-life management of carbon fiber waste poses a significant environmental challenge. Traditional disposal methods, including incineration and landfilling, are not sustainable. Recent advancements in carbon fiber recycling have fostered sustainable solutions across multiple industries.

Dr. Michael Gaultois is the Chief Scientific Officer of Fairmat, a deeptech startup that uses material science, AI and robotics to recycle carbon fiber composite and manufacture products. Before joining Fairmat in 2022, Michael led research at the interface of Materials Science and AI, developing novel methods and functional materials with applications in sustainability and energy. Michael has held numerous prestigious international fellowships, including a Fulbright International Science and Technology Fellowship at the University of California Santa Barbara, a Marie Skłowdowska–Curie Fellowship at the University of Cambridge, and a Ramsay Memorial Fellowship at the University of Liverpool.

Really good router bit. I've given mine a real punishment, deep cuts into rosewood and a hard mahogany and it still cut well. My bits were delivered extra fast. Probably the best 1/8 inch bit with more than 1/2 inch depth on the market.

Mechanical recycling: Mechanical recycling involves physically breaking down carbon fiber composites into smaller pieces using advanced machinery. This process is energy-efficient because it does not use high temperatures. However, traditional methods like grinding and crushing can shorten the fiber lengths, reducing their quality and strength. Deeptech startup Fairmat has developed an innovative robotic system that mechanically cuts the fibers while preserving their mechanical properties, making them suitable for reuse.

I had previously been doing all my slab flattening on a home made sled. It worked ok and it got the job done, but it had many limitations, some of which I didn't even realize until I started using the SpeTool sled. The first issue was that it had too much flex in the wood rails and would sag when I tried flatting slabs larger than about 20" wide. The second issue was the mess it made in the shop. It was actually so bad that I would have to use it outside. The biggest draw back however, wasn't realized until I started using the SpeTool sled. With the SpeTool sled I was able to work the router with the grain down the long side of the Slab This was something that I couldn't really do with my homemade sled. Working with the grain produces a smoother surface and is less work in my opinion. Then when you add in the dust collection, I was able to work in my shop again. Now I am not going to say you won't need to vacuum when you are done, but the mess is drastically less than with no dust collection. Also, the aluminum rails are much stiffer than my wood ones and don't flex nearly as much over larger spans. I would absolutely put this kit at the top of my list if I was setting a small garage shop up for slab flattening. Rob @ RM Woodcraft llc

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The impact of carbon fiber recycling extends beyond individual companies. Industry-wide adoption of recycling technologies can significantly reduce the environmental impact of various sectors, including wind energy. This supports global sustainability goals and enhances the economic viability of using recycled materials by reducing costs.

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This degree prepares you for entry-level positions in machining and manufacturing. You explore lathe turning and milling operations.

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Several innovative processes have emerged to address carbon fiber waste, turning it into valuable resources. Mechanical recycling, thermal recycling and chemical recycling are key methods. Each process involves breaking down carbon fiber composites to recover fibers that can be reused in various applications:

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Despite the advancements, challenges remain in scaling up recycling processes and ensuring economic feasibility. Research and development efforts are crucial in overcoming these hurdles and improving recycling efficiency. Future directions include enhancing the quality of recycled fibers and developing new applications for recycled materials. Collaboration within the industry ecosystem is essential to maximizing impact.

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Mechanical recycling is the primary method used by Fairmat. This involves proprietary cutting technologies and the use of advanced machinery, robotics and artificial intelligence (AI). Importantly, unlike traditional grinding or crushing, Fairmat’s proprietary cutting technology mechanically breaks down the carbon fiber composites into smaller pieces while preserving the mechanical properties of the fibers, making them suitable for reuse in high-performance applications. Robotic tools and AI enhance the precision and efficiency of this process, converting the carbon fiber components into CFRP (carbon fiber reinforced polymer) building blocks. This is a unique and sustainable technology that combines material science, data informatics and robotics, permitting the recycling of a broad range of carbon feedstocks (uncured and EOL products). This innovative process creates recycled carbon fiber that can be used for applications such as interior structural reinforcements, impact surfaces and exterior design finishings. By seamlessly integrating advanced recycled material both inside and outside products poised to enhance electronics, sporting goods, mobility and beyond, Fairmat is not only redefining industries but also setting new benchmarks for innovation and environmental stewardship.

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Only having used this tool a couple of times, I am completely satisfied with it's performance. I have used the bit to flush trim a few patterns in walnut and white oak. This bit moved right through the wood. The cut was very smooth. I am also happy that I will be able to turn / swap out the cutters.

Fairmat’s recycling process begins with the collection and segregation of carbon fiber waste from various sources. The waste materials, which can include prepregs, offcuts and end-of-life (EOL) products, are carefully segregated to identify those suitable for recycling. Upon arrival at Fairmat’s facilities, the collected waste undergoes further segregation and preprocessing. This step ensures that the materials are in optimal condition for recycling. Preprocessing treatments, such as cleaning and cutting, are applied to prepare the carbon fiber waste for the next stage.

Recycling carbon fiber is a vital component of the sustainability strategy across multiple high-performance industries. By transforming waste into valuable resources, the industry can significantly reduce its environmental footprint and move closer to achieving a circular economy.

This is an investment! That being said, if you only doing one slab, I would recommend DIY build or having someone professionally flatten your project. I would hazard a guess that you would be saving for a fifth of the cost of this rig. I bought the dust shield with vacuum hose attachment and was disappointed on a few levels. Firstly, it's a gimmick that falls short of its intended purpose and although it may cut down a little of the waste being scattered in the shop, it does not work as advertised. Do your slab flattening outside or you'llbe vacuuming for days. Secondly the hose port fit is not standard for any shop vac, so you'll be needing some type of adapter. As for the router sled itself, the build is sturdy, and it does work as intended. However there is the minimal clearance issue. Even at its lowest setting, I still had to raise the work piece as the plunge depth of routers are limited. Also expect to clear debris (constantly) from wheel path as it collects and will hinder the smoorh and level tracking of the wheels Overall, it works. But I'm thinking I should have opted for the bearing rail system. I gave it 3 stars because that's where it falls in the overall rating. Average! These are my opinions from my experience. Your millage may vary. If I could send it back without the hassle. I probably would. I don't have the box, and the return policy says everything has to be in original unused condition, which is impossible after use.

Carbon fiber reinforced polymers (CFRP) are crucial for industries that require materials with exceptional strength-to-weight ratios. However, their production and disposal are energy-intensive processes. Recycling carbon fiber helps conserve resources and reduce the carbon footprint associated with manufacturing new materials.