Reuse and upcycling of thermoset prepreg scrap: Case study with out-of-autoclave carbon fiber/epoxy prepreg

A large amount of uncured thermoset prepreg scrap is generated during manufacturing, including both ply cutter trim waste and out-of-spec material. While techniques to recycle end-of-life cured composite waste and reclaim carbon fiber are well established and commercialized, there is little effort made presently towards reusing uncured scrap prepreg. Here, we present a viable and scalable technique to process scrap prepreg into intermediate forms that can be readily manufactured into commercial end-products. Using out-of-autoclave carbon fiber/epoxy prepreg as an example, we report the mechanical properties, microstructure, and performance of composite laminates fabricated with scrap prepreg under various processing conditions. Demonstrator parts manufactured with scrap prepreg are also presented.