| 1. |
EXECUTIVE SUMMARY |
| 1.1. |
Report introduction |
| 1.2. |
Overview of the composite materials market |
| 1.3. |
Introduction to composite materials |
| 1.4. |
Glass fiber vs Carbon fiber reinforced polymers |
| 1.5. |
Thermoset vs thermoplastic composites |
| 1.6. |
Composite material suppliers |
| 1.7. |
Overview of manufacturing methods for composite materials |
| 1.8. |
Volume of composite materials reaching end of life |
| 1.9. |
Sustainable composites market drivers: Government regulation |
| 1.10. |
Composite End-of-Life Pathways |
| 1.11. |
Why is composite recycling traditionally challenging and limited? |
| 1.12. |
Companies working to recycle end of life composites – Development stage |
| 1.13. |
Overview of the types of sustainable composite materials discussed in this report |
| 1.14. |
Comparison of recyclable and traditional resin systems |
| 1.15. |
Recyclable resin systems – market landscape |
| 1.16. |
Natural fibers offer light weighting incentives but lower mechanical strengths |
| 1.17. |
Bio resins can act as drop-in replacements to traditional synthetic resins |
| 1.18. |
Composites for green energy applications |
| 1.19. |
Thermal resistance remains a concern for composite EV battery casings |
| 1.20. |
Composites are enabling growth of the hydrogen economy |
| 1.21. |
Wind turbine blade waste is set to grow significantly |
| 1.22. |
The major companies developing recyclable resins for the wind turbine blade market |
| 1.23. |
GFRP composites could be a promising alternative to aluminium solar frames |
| 1.24. |
Tidal turbines require high durability marine-grade composites |
| 1.25. |
Significant improvements to composite thermal stability are required for geothermal applications |
| 1.26. |
Composite material demand for green energy forecast |
| 1.27. |
Composite material revenue for green energy forecast |
| 1.28. |
Outlook for sustainable composite materials |
| 1.29. |
Outlook for sustainable composites continued |
| 1.30. |
Outlook for composite materials for green energy |
| 1.31. |
Outlook for composite materials for green energy continued |
| 2. |
MARKET FORECASTS |
| 2.1. |
Methodology and assumptions |
| 2.2. |
Composites for green energy applications market demand |
| 2.3. |
Composites for green energy applications market value |
| 2.4. |
Composites for electric vehicle battery casing demand |
| 2.5. |
Composites for electric vehicle battery casings revenue |
| 2.6. |
Composites for FCEV hydrogen pressure vessels demand |
| 2.7. |
Composites for FCEV hydrogen pressure vessels revenue |
| 2.8. |
Composites for wind turbine blades demand |
| 2.9. |
Composites for wind turbine blades revenue |
| 2.10. |
Composite wind turbine blade waste forecast |
| 2.11. |
Composites for solar panel demand |
| 2.12. |
Composites for solar panel revenue |
| 3. |
INTRODUCTION TO COMPOSITE MATERIALS |
| 3.1. |
Overview of the composite materials market |
| 3.2. |
Overview of composite materials |
| 3.3. |
Why are composite materials useful? |
| 3.4. |
Definition of terms used in this report (I) |
| 3.5. |
Definition of terms used in this report (II) |
| 3.6. |
Key factors influencing composite properties |
| 3.7. |
Composite reinforcement materials |
| 3.8. |
Overview of carbon fiber |
| 3.9. |
Overview of glass fiber |
| 3.10. |
Fiber forms (I) |
| 3.11. |
Fiber forms (II) |
| 3.12. |
Polymer matrix composites (PMC) and resin systems |
| 3.13. |
Overview of resin systems (I) |
| 3.14. |
Overview of resin systems (II) |
| 3.15. |
Glass fiber vs Carbon fiber reinforced polymers |
| 3.16. |
Thermoset vs thermoplastic composites |
| 3.17. |
Composite material uses |
| 3.18. |
Composites for green energy applications |
| 3.19. |
Introduction to sustainable composites |
| 3.20. |
Overview of the types of sustainable composite materials discussed in this report |
| 3.21. |
Sustainable composites market drivers: Government regulation |
| 3.22. |
Volume of composite materials reaching end of life |
| 3.23. |
Composite End-of-Life Pathways |
| 4. |
COMPOSITE MATERIALS AND MANUFACTURING |
| 4.1. |
Composite materials and manufacturing routes influence end product properties |
| 4.2. |
Fiber Reinforcement Properties |
| 4.3. |
Cost of Fiber Reinforcements |
| 4.4. |
Innovations to lower the cost and energy intensity of carbon fiber manufacturing |
| 4.5. |
Types of resin systems |
| 4.6. |
Materials for Composite Cores |
| 4.7. |
Material suppliers |
| 4.8. |
Overview of the composite manufacturing value chain |
| 4.9. |
Overview of manufacturing methods for composite materials |
| 4.10. |
Pre-Preg Composites – Fabric type |
| 4.11. |
Hand Lay-up / Wet Lay-up |
| 4.12. |
Spray Lay-up |
| 4.13. |
Injection molding |
| 4.14. |
Compression molding |
| 4.15. |
Resin Transfer molding (RTM) |
| 4.16. |
Vacuum Assisted Resin Transfer molding (VARTM) |
| 4.17. |
Pultrusion |
| 4.18. |
Filament Winding |
| 4.19. |
Autoclave Curing (Prepreg Lay-up) |
| 4.20. |
Automated fiber placement – streamlining composite manufacturing |
| 4.21. |
Comparison of traditional composite manufacturing methods |
| 5. |
METHODS TO RECYCLE COMPOSITE COMPONENTS |
| 5.1. |
Introduction to recycling composites |
| 5.2. |
Why is composite recycling traditionally challenging and limited? |
| 5.3. |
Desire for a circular economy |
| 5.4. |
Global Composite and Solid Waste Regulations (I) |
| 5.5. |
Global Composite and Solid Waste Regulations (II) |
| 5.6. |
Global Composite and Solid Waste Regulations (III) |
| 5.7. |
Life Cycle Analysis (LCA) |
| 5.8. |
Material Traceability – Implementation of digital product passports |
| 5.9. |
The four types of recycling: Process definitions |
| 5.10. |
Composite End-of-Life Pathways |
| 5.11. |
What is mechanical recycling? |
| 5.12. |
Mechanical recycling of composites – Case studies |
| 5.13. |
What is Thermal Recycling – Pyrolysis? |
| 5.14. |
Pyrolysis recycling of composites – Case studies |
| 5.15. |
What is chemical recycling? |
| 5.16. |
Chemical recycling of composites – Case studies |
| 5.17. |
Companies working to recycle end of life composites – Development stage |
| 5.18. |
Volume of composite materials reaching end of life |
| 5.19. |
Acciona – Recycling of end-of life wind turbine blades |
| 5.20. |
Cygnet Texkimp’s composite recycling technology |
| 5.21. |
Vartega- Recycling carbon fiber |
| 5.22. |
Composite Recycling – Thermolysis Recycling Technique |
| 5.23. |
Fraunhofer’s wetlaid facility for carbon fiber processing |
| 5.24. |
Anmet – Repurposing and Recycling Wind Turbine Blades |
| 5.25. |
ZEBRA project – IRT Jules Verne |
| 5.26. |
REFRESH project – circular recycling of composite wind turbine blades |
| 5.27. |
Overview of composite recycling companies |
| 5.28. |
Overview of composite recycling companies |
| 5.29. |
Summary of Composite Recycling |
| 6. |
RECYCLABLE COMPOSITES |
| 6.1. |
Introduction to recyclable composite materials |
| 6.2. |
Recyclable resin systems |
| 6.3. |
Dynamic Covalent Bonds for Polymer Reprocessing – Vitrimers |
| 6.4. |
Vitrimers SWOT |
| 6.5. |
Thermoplastics offer inherent processability |
| 6.6. |
Recyclable resin systems – market landscape |
| 6.7. |
Evonik – Recyclable foam cores |
| 6.8. |
Armacell – Recyclable PET foams |
| 6.9. |
Aditya Birla – Recyclamine |
| 6.10. |
Arkema – Elium |
| 6.11. |
Westlake Epoxy – EpoVIVE |
| 6.12. |
Techstorm – Vitrimer Resins |
| 6.13. |
Swancor – EzCiclo |
| 6.14. |
METOL – CBT/PBT |
| 6.15. |
Other companies developing recyclable resins |
| 6.16. |
Overview of the companies developing recyclable resin systems |
| 6.17. |
Comparison of recyclable and traditional resin systems |
| 6.18. |
Summary for recyclable composite materials |
| 7. |
BIO-BASED COMPOSITES |
| 7.1. |
Introduction to bio-composites |
| 7.2. |
Challenges of using bio-composites |
| 7.3. |
Natural fibers |
| 7.4. |
What are natural fibers? |
| 7.5. |
Global production of natural fibers |
| 7.6. |
The advantages and disadvantages of natural fiber-based composites |
| 7.7. |
Natural fibers require surface modifications for composite use |
| 7.8. |
Benchmarking of composite fiber reinforcements |
| 7.9. |
Case study: Bio-derived resins with natural fibers |
| 7.10. |
Case study: Hemp fibers for bio-composites |
| 7.11. |
Natural fiber consortium group |
| 7.12. |
Flax-based bio-composites for automotive applications |
| 7.13. |
Example Bcomp products at JEC world |
| 7.14. |
Ecotechnilin |
| 7.15. |
Changchun Bochao Auto Parts |
| 7.16. |
Other natural fiber products |
| 7.17. |
Natural fibers SWOT |
| 7.18. |
Outlook for natural fibers within the green energy transition |
| 7.19. |
Bio-Resin Systems |
| 7.20. |
Introduction to bio-resin systems |
| 7.21. |
What are bio-polymers? |
| 7.22. |
Types of bio-resin systems |
| 7.23. |
Bio-epoxy resin properties, application and opportunities |
| 7.24. |
Bio unsaturated polyester resins |
| 7.25. |
Bio PFA resins properties, application and opportunities |
| 7.26. |
Bio-polyamide resins |
| 7.27. |
Bio-polyurethane resin coatings |
| 7.28. |
Could bio-degradable polymers be used for composites? |
| 7.29. |
Improving mechanical properties of bio-composites with cellulose additives |
| 7.30. |
Overview of the companies supplying bio-resins |
| 7.31. |
Westlake Epoxy – EpoVIVE bio epoxy resins |
| 7.32. |
Entropy Resins – Bio epoxy |
| 7.33. |
Cathay Biotech – Bio polyamide resins |
| 7.34. |
Arkema – Bio polyamide resin |
| 7.35. |
Applied Bioplastics – Bio-based composites for construction |
| 7.36. |
Case studies: Use of bio-resin systems in industry |
| 7.37. |
Overview of the companies developing bio-resins for composites (I) |
| 7.38. |
Overview of the companies developing bio-resins for composites (II) |
| 7.39. |
Outlook for bio-resins for composites |
| 8. |
APPLICATIONS FOR COMPOSITES IN GREEN ENERGY |
| 8.1.1. |
Composites for green energy applications |
| 8.2. |
Composites for EV batteries |
| 8.2.1. |
What is an electric vehicle? |
| 8.2.2. |
Overview of EV battery components and materials |
| 8.2.3. |
What’s in an EV Battery Pack? |
| 8.2.4. |
Major Challenges in EV Battery Design Overview |
| 8.2.5. |
Methods for Materials Suppliers to Improve Sustainability for the OEM |
| 8.2.6. |
Battery Pack Enclosures |
| 8.2.7. |
Battery Enclosure Materials and Competition |
| 8.2.8. |
Requirements for effective battery pack enclosures |
| 8.2.9. |
Moving Towards Composite Enclosures |
| 8.2.10. |
Are Polymer Composites Suitable Battery Housings? |
| 8.2.11. |
Project for Composite EV Battery Enclosure Development |
| 8.2.12. |
GFRP Enclosure for HV Battery – Envalior |
| 8.2.13. |
Thermoplastic Composite Battery Packs – SABIC |
| 8.2.14. |
Sheet molded compounds vs resin transfer or liquid compression molding |
| 8.2.15. |
SMC for Battery Trays and Lids – LyondellBasell |
| 8.2.16. |
SMC EV Battery Cover – Hankuk Carbon |
| 8.2.17. |
Advanced Composites for Battery Enclosures – INEOS Composites / ALTA Performance Materials |
| 8.2.18. |
Biobased Battery Pack Enclosure – Cathay Biotech |
| 8.2.19. |
Composite EV battery impact protection plate – Autoneum |
| 8.2.20. |
Alternatives to Phenolic Resins |
| 8.2.21. |
Other composite battery enclosure suppliers |
| 8.2.22. |
Examples of composite battery enclosures for EVs |
| 8.2.23. |
Battery Enclosure Materials Summary |
| 8.2.24. |
Energy Density Improvements with Composites |
| 8.2.25. |
Cost Effectiveness of Composite Enclosures |
| 8.2.26. |
Fire protection and EMI shielding for composites |
| 8.2.27. |
Thermal Runaway and Fires in EVs |
| 8.2.28. |
Thermal Runaway in Cell-to-pack |
| 8.2.29. |
Fire protection regulations for EV batteries |
| 8.2.30. |
Fire Protection Materials: Main Categories |
| 8.2.31. |
EMI Shielding for Composite Enclosures |
| 8.2.32. |
Integrating EMI shielding in composites – James Cropper |
| 8.2.33. |
Flame resistant thermosetting composites – IDI Composites |
| 8.2.34. |
Graphite Additives for Reactive Coatings – NeoGraf |
| 8.2.35. |
Polymers addressing thermal runaway (1) – Ascend Performance Materials |
| 8.2.36. |
Polymers addressing thermal runaway (2) – SABIC |
| 8.2.37. |
Polymers addressing thermal runaway (3) – Asahi Kasei |
| 8.2.38. |
Flame-retardant Plastics – Covestro |
| 8.2.39. |
LG Chem – Fire Protection Plastic and Barrier Materials |
| 8.2.40. |
SABIC’s Multifunctional PP STAMAX |
| 8.2.41. |
Pyrophobic Systems |
| 8.2.42. |
CFP Composites |
| 8.2.43. |
Elven Technologies |
| 8.2.44. |
Nonwoven fabric for thermal runaway protection – Asahei Kasei |
| 8.2.45. |
Summary of composites for EV battery packs |
| 8.3. |
Composite for Hydrogen Pressure Vessels |
| 8.3.1. |
Overview of hydrogen pressure vessels |
| 8.3.2. |
Compressed hydrogen storage |
| 8.3.3. |
Hydrogen storage tanks |
| 8.3.4. |
Stationary storage systems |
| 8.3.5. |
Compressed tube trailers |
| 8.3.6. |
Compressed storage vessel classification |
| 8.3.7. |
Construction materials for Type 3 and 4 vessels |
| 8.3.8. |
Applications for Type 3 & 4 tanks |
| 8.3.9. |
Players in Type 3 & 4 technologies |
| 8.3.10. |
Type 5 hydrogen storage is emerging |
| 8.3.11. |
Onboard FCEV tank suppliers |
| 8.3.12. |
Material & manufacturing considerations for pressure vessels |
| 8.3.13. |
Composite tank failure |
| 8.3.14. |
Liner materials for Type III & IV vessels |
| 8.3.15. |
Composite material choice for pressure vessels |
| 8.3.16. |
Fiber materials for Type III & IV vessels |
| 8.3.17. |
Manufacturing composite hydrogen pressure vessels – filament winding |
| 8.3.18. |
Automated fiber placement manufacturing – emerging pressure vessel manufacturing technique |
| 8.3.19. |
Cryogenic composite tanks for aerospace |
| 8.3.20. |
Cevotec – FPP and Filament Winding in Action |
| 8.3.21. |
CONBILITY – Machine systems for hydrogen pressure vessel production |
| 8.3.22. |
AZL – Hydrogen pressure vessel optimization potential in various materials |
| 8.3.23. |
Summary |
| 8.4. |
Composites for Wind Energy |
| 8.4.1. |
Introduction to the wind energy sector |
| 8.4.2. |
European wind energy market |
| 8.4.3. |
APAC wind energy market |
| 8.4.4. |
Americas wind energy market |
| 8.4.5. |
Wind installations by country (I) |
| 8.4.6. |
Wind installations by country (II) |
| 8.4.7. |
China’s dominance of the wind energy sector |
| 8.4.8. |
Global approach to wind turbine manufacturing by Chinese players |
| 8.4.9. |
Further details on China’s global approach |
| 8.4.10. |
Traditional wind turbine structure and materials |
| 8.4.11. |
Traditional wind turbine blade structure and materials |
| 8.4.12. |
Wind turbine blade size growth |
| 8.4.13. |
Hybrid carbon/glass fiber wind turbine blades |
| 8.4.14. |
Traditional methods to manufacture wind turbine blades |
| 8.4.15. |
Advanced manufacturing techniques for wind turbine blades |
| 8.4.16. |
Traditional wind turbine blades are inherently difficult to recycle |
| 8.4.17. |
Wind turbine end-of-life management – who pays? |
| 8.4.18. |
Wind farm end-of-life management – Repowering wind farms |
| 8.4.19. |
Wind turbine blade waste is set to grow significantly |
| 8.4.20. |
Recyclable resins for wind turbine blades overview |
| 8.4.21. |
Comparison of resins for wind turbine blades |
| 8.4.22. |
Wind turbine blade supply chain |
| 8.4.23. |
Global wind turbine manufacturing capacity by company |
| 8.4.24. |
Companies working to recycle wind turbine blades |
| 8.4.25. |
RecyclableBlade – Siemens Gamesa |
| 8.4.26. |
Biobased and recyclable resins for wind blades – Westlake Epoxy |
| 8.4.27. |
EzCiclo recyclable resin for wind turbine blades – Swancor |
| 8.4.28. |
Recyclamine recyclable thermoset resin – Aditya Birla |
| 8.4.29. |
Elium thermoplastic resin for wind blades – Arkema |
| 8.4.30. |
Vitrimer resins enable recyclability and high durability – Techstorm |
| 8.4.31. |
Summary of the companies developing recyclable resin systems for wind turbine blades |
| 8.4.32. |
Bio-based resins for the wind energy sector |
| 8.4.33. |
Exploring circularity in the wind industry – Armacell |
| 8.4.34. |
Traditional wind turbine blade materials at JEC World 2025 |
| 8.4.35. |
Balsa wood – encouraging the sustainable wood sourcing for wind turbine blades |
| 8.4.36. |
Vertical axis wind turbines are better suited to urban use |
| 8.4.37. |
Modular wind turbine blades – Carbo4Power |
| 8.4.38. |
Summary of Sustainable Composites for Wind Turbine Blades |
| 8.5. |
Other renewable energy applications |
| 8.5.1. |
Overview of other renewable energy applications of composites |
| 8.5.2. |
Composites for Solar Energy |
| 8.5.3. |
Introduction to the solar industry |
| 8.5.4. |
What is a solar panel? |
| 8.5.5. |
Traditional solar panelling materials |
| 8.5.6. |
Composite material use for solar energy – moving away from aluminium |
| 8.5.7. |
Comparison of composite solar framing vs aluminium frames |
| 8.5.8. |
Total cost of ownership by solar frame type |
| 8.5.9. |
Glass fiber PU composite frames from solar panels – Covestro |
| 8.5.10. |
Carbon fiber for solar energy – Levante |
| 8.5.11. |
Bio-based composites for the solar energy industry |
| 8.5.12. |
Summary of composites for solar energy |
| 8.5.13. |
Composites for Tidal Energy |
| 8.5.14. |
Introduction to tidal power |
| 8.5.15. |
Types of tidal power systems |
| 8.5.16. |
Pros and Cons of tidal power |
| 8.5.17. |
Horizontal axis turbines are the primary turbine choice |
| 8.5.18. |
Tidal turbine projects and deployments |
| 8.5.19. |
Performance and design requirements for tidal turbine hydrofoils |
| 8.5.20. |
Composite materials for tidal turbine blades |
| 8.5.21. |
Thermoplastic tidal turbines – a recyclable resin alternative |
| 8.5.22. |
Resin matrix materials – moisture and corrosion resistance |
| 8.5.23. |
Summary of composites for tidal energy |
| 8.5.24. |
Composites for Geothermal power |
| 8.5.25. |
Introduction to Geothermal Energy |
| 8.5.26. |
Geothermal energy installations globally |
| 8.5.27. |
Global tectonic plates and boundaries – sources of geothermal energy |
| 8.5.28. |
How does geothermal power work? |
| 8.5.29. |
Comparison of the types of geothermal power plant |
| 8.5.30. |
Geothermal power plant material performance requirements |
| 8.5.31. |
The components for geothermal power – composite material options |
| 8.5.32. |
The feasibility of all-composite geothermal well pipes |
| 8.5.33. |
Huisman composite tubulars |
| 8.5.34. |
Composite pipes for low-enthalpy geothermal energy – Future Pipe Industries |
| 8.5.35. |
Summary of composites for geothermal energy |
| 8.5.36. |
Company Profiles |
