ELG Carbon Fibre, a market leader in recycled carbon fibre materials, has started production of a range of nonwoven mats on a new production line, designed to process recycled carbon fibres. The mats are available in widths up to 2.7 metres at a wide range of fibre areal weights, useful in the transportation sector for vehicle lightweighting. The new machine has been custom-built to ELG Carbon Fibre’s exacting specifications. Designed and manufactured in the UK, it can produce a variety of nonwoven materials including 100 per cent recycled carbon fibre mats and thermoplastic blends such as carbon fibre mixed with PP, PA, PPS fibres. Extensive reconfiguration of the standard nonwoven manufacturing process was required to ensure the equipment could accept and process recycled carbon fibres. Special adaptations were made to limit fibre loss, breakage, and cleaning cycles. The machine is also unique in being able to use reclaimed carbon fibres that have been obtained through pyrolysis of scrap prepreg materials or cured laminates, providing important feedstock flexibility versus existing equipment available in the marketplace which can only accept dry manufacturing waste. The equipment features a flexible, modular-based design that allows easy extension of its initial capacity of 250mt/pa to a maximum output of 1000mt/pa within 9-12 months as customer demand increases. It can produce webs ranging from 100gsm-500gsm at widths up to 2.7 metres and, depending on the final mat thickness, roll lengths will range from 30-50 metres. The Carbiso M and TM product ranges demonstrate excellent drapeability and performance while delivering cost effective light weighting and significant environmental benefits. ELG Carbon Fibre’s Carbiso M mats are ideally suited for closed mould processes and can also be used for the manufacture of intermediate products such as prepregs and sheet moulding compounds for composite manufacturing. The thermoplastic Carbiso TM mats are designed for fast cycle times in press moulding applications.