The HiPeR project, funded under grant 03INT713AA and carried out from 1 April 2020 to 31 March 2023, aimed to improve the mechanical performance of recycled carbon‑fiber (rCF) half‑objects for aerospace use. The main technical objective was to increase the fiber alignment within the rCF fabrics so that the resulting material would exhibit strength and fatigue properties comparable to virgin carbon‑fiber composites while keeping recycling costs low. The project demonstrated that highly aligned rCF fabrics can indeed meet or exceed the target mechanical values set at the outset. Seven different rCF fabrics, produced from five distinct raw materials, were fabricated into flat plates and subjected to destructive testing by GMA‑Werkstoffprüfung Stade GmbH. The measured tensile and flexural strengths of the best performing fabrics surpassed the initial target values, confirming that the alignment strategy was effective. The high fiber orientation also translated into improved fatigue resistance, a key requirement for aircraft structural components.

The technical work progressed through a clear sequence. First, the Saxon Textile Research Institute (STFI) produced the rCF half‑objects according to the specifications developed by CTC GmbH. CTC then fabricated test specimens and coordinated the destructive testing with GMA. The data from these tests guided a material selection process that identified the most promising rCF fabrics. In parallel, CTC defined the aerospace target part in collaboration with Airbus Stade, the original equipment manufacturer. The chosen part was the upper rib of the vertical stabilizer (VTP) of the Airbus A320, a component that offers a realistic test case for rCF application.

With the material selected, CTC proceeded to manufacture a demonstrator rib using the Resin‑Transfer Moulding (RTM) process. Because the project budget did not allow for the purchase of a new complex mould, an existing tool was adapted. Layer‑by‑layer builds of the rCF fabric were inserted into the mould, resin was injected, and the part was cured. Seven demonstrator ribs were produced over successive iterations. Visual inspection and dimensional checks showed progressive quality improvements, especially in the later samples, indicating that the combination of RTM and highly aligned rCF fabrics is suitable for producing aerospace‑grade components. Although internal quality analysis could not be performed within the project, the mechanical data from the test specimens and the visual assessment of the demonstrators support the conclusion that the process yields parts with acceptable structural integrity.

The consortium comprised CTC GmbH, which coordinated the German partners and led the mechanical evaluation, STFI, which supplied the rCF half‑objects, GMA, which performed the destructive testing, Airbus Stade, which defined the target part and provided industry context, and C.A.R. FiberTec GmbH, which contributed to material selection. The project was financed by the German Federal Ministry of Education and Research, as indicated by the grant number. The overall outcome of HiPeR is a validated pathway to produce high‑performance recycled carbon‑fiber composites that can be integrated into aircraft structures, thereby improving the price‑performance ratio of recycled materials and advancing circular economy principles in the aerospace sector.