The sustainability spectrum of carbon fibre: balancing high performance CFRP composites with environmental responsibility

Carbon fibre, renowned for its exceptional strength-to-weight ratio, plays a pivotal role in advancing clean technologies such as renewable energy systems and lightweight transportation, thereby contributing to a more sustainable economy. However, the production of carbon fibres and their composites presents a paradox: while it enables significant environmental benefits through various end-use applications, the manufacturing processes are highly energy-intensive and reliant on synthetic resins, which are often non-recyclable. This review critically examines the sustainability of carbon fibre through a comprehensive analysis of life cycle assessment (LCA) studies, highlighting the environmental and economic impact of carbon fibre composite production, use, and recycling. Additionally, the paper explores the latest advancements in using recyclable polymer resins, and remanufacturing and the alignment methods of recycled carbon fibres, which offer promising pathways for improving the circularity of carbon fibre composites. By critically evaluating these aspects, the paper aims to provide insights into the current challenges and potential solutions for making carbon fibre a truly sustainable material in the context of a clean economy.