Daher Group Builds Value Chain to Enable Upcycling of Thermoplastic Composites

For more than a decade, Dach Group has consistently invested resources to focus on thermoplastic composite materials technology, to meet the needs of aerospace projects in terms of structural weight reduction, lower carbon footprint, and efficient mass production. Its high-load thermoplastic composite wing rib product won the 2026 JEC Award in the Aerospace (Component) category, which is a strong testament to its professional expertise in this field.

Daher Group has now taken a new step by establishing a complete upgraded recycling value chain, covering the entire process from waste collection to the reintroduction of materials into production. This initiative aims to reintegrate such materials into a new manufacturing cycle, achieving both environmental benefits and enhanced industrial self-reliance.

Upgrade 100% pure carbon-based PPS waste into pellet with 56% carbon fiber.

One of the core elements of this strategy is the upgrading and recycling of waste generated during the production of thermoplastic composite parts. Daher Group collaborates closely with its Saint-Aignan-de-Granjou factory in the Loire-Atlantique department in France, as well as its Shap'in technology center, to establish a standardized process: on-site collection of production waste, followed by crushing at the Shap'in technology center, and then processing into semi-finished materials.

Currently, the process can achieve 100% upcycling of pure carbon-based polyphenylene sulfide (PPS) waste. The final semi-finished product is in the form of pellets, with a carbon fiber content of 56%. This material, transformed from the original continuous fibers into short fibers, boasts excellent mechanical properties, including outstanding high-temperature resistance, moisture resistance, and chemical corrosion resistance. It is especially suitable for injection molding processes, used for manufacturing complex and precise components that can withstand harsh operating conditions.

With the scale-up of this process, the annual production capacity of carbon-based PPS pellets is expected to reach 4 to 8 tons. Daher Group currently has 1.5 tons of this product available for sale and is actively expanding customer applications beyond the aerospace sector. Recently, the group has also developed a filament from similar waste material suitable for additive manufacturing, opening new possibilities for 3D printing of precision components. Parts produced using this filament were showcased at Daher Group’s booth at the JEC World Composites Exhibition in 2026.

Upgrading and Recycling of Retired Aerospace Components

In addition to production waste, Daher Group also applies its technical capabilities to the recycling and reutilization of retired aerospace components made from thermoplastic composites.

The technology was recognized in the 2026 JEC Innovation Awards, and the project led by the Group in collaboration with Airbus, Toray Advanced Composites, and Tarmac Aerosave won another award. The project recycled, cut, and reused thermoplastic composite panels from an A380 aircraft for the production of new components for the A320neo model. The finished products were also exhibited at the Daheng Group's booth at the 2026 JEC World Composites Exhibition.

This demonstration verified that the Dahe Group has the technological capability for full-scene thermoplastic composite material upcycling, covering various materials from production waste to retired structural components, and can prepare for the industrialization of relevant solutions.

Daher Group's Vice President of R&D, Julie Vodure, stated: "For over a decade, we have continuously invested in the thermoplastic composites field to meet the needs of aircraft manufacturers in terms of production efficiency, structural weight reduction, and product performance. Now, we have taken a further step, achieving the industrial application of upgraded recycled materials. This technological capability enables us to optimize the utilization efficiency of strategic materials, strengthen material self-supply capabilities, and explore new application scenarios in aerospace and many other fields."