Daher accelerates the industrialization of thermoplastic composite revalorization

On the occasion of JEC World 2026 (Paris Nord Villepinte, March 10–12, 2026), Daher confirms its role as a pioneering industrial player in the revalorization of thermoplastic composites. Among the first actors to initiate the transition to industrial scale, the Group is preparing to make these revalorized materials available to manufacturers facing the challenges of ramping up production rates, material sovereignty, and decarbonization. Two projects were distinguished at the JEC Innovation Awards.

Orly, March 9, 2026 – For more than ten years, Daher has been investing in mastering thermoplastic composites to meet the requirements of aerospace programs: lighter structures, reduced carbon footprint, and high-rate production. The JEC Award 2026 won in the Aeronautics (Parts) category for its highly loaded thermoplastic wing rib is a demonstration of this.

Today, the Group is taking a new step by structuring a complete revalorization chain, from the collection of offcuts to the reintroduction of the material into production. The objective: to reintegrate these materials into new manufacturing cycles, with a dual environmental and industrial sovereignty benefit.

Revalorization of thermoplastic offcuts: an industrialized technical material

The first pillar of this strategy relies on the revalorization of offcuts resulting from the production of thermoplastic composite parts. In close connection with its Saint-Aignan-de-Grandlieu plant (Loire-Atlantique) and its Shap’in Techcenter, Daher has implemented a structured process: offcuts are collected on site, ground at Shap’in, and then transformed into a semi-finished product.

Today, 100% of pure carbon PPS offcuts are revalorized through this process. The semi-finished product obtained is a pellet containing 56% carbon fiber. Derived from fibers that were initially continuous and reconfigured into short fibers, it exhibits high mechanical properties: excellent temperature resistance, strong resistance to humidity, and resistance to chemical attack. Particularly suited to injection processes, this material enables the manufacture of complex technical parts intended for demanding environments.

The ramp-up of this process translates into an estimated capacity of between 4 and 8 tonnes per year of carbon PPS pellets. Daher currently has a stock of 1.5 tonnes available for sale and is actively working on customer applications, including beyond the aerospace sector. Recently, using these same offcuts, the Group developed a filament intended for additive manufacturing, opening new prospects for the 3D printing of technical parts. A part produced using additive manufacturing with this filament is displayed on the Daher stand at JEC World 2026.

Revalorization of end-of-life aeronautical parts

In addition to the revalorization of production offcuts, Daher is also deploying its expertise on end-of-life thermoplastic composite aeronautical parts.

This approach was distinguished at the JEC Innovation Awards 2026, with a second award-winning project carried out in partnership with Airbus, Toray Advanced Composites, and Tarmac Aerosave. It involved recycling thermoplastic composite panels from an A380, then cutting them and reintegrating them into the manufacture of new parts intended for the A320neo. The part produced as part of this project is displayed on the Daher stand at JEC World 2026.

This demonstration confirms Daher’s ability to master the revalorization of thermoplastic composites in all their forms, from production offcuts to end-of-life structures, and to prepare their transition to industrial scale.

“For more than ten years, we have been investing in thermoplastic composites to meet aircraft manufacturers’ requirements in terms of production rate, weight reduction, and performance. Today, we are taking a further step by industrializing the material resulting from its revalorization. This capability allows us to optimize the use of a strategic material, strengthen our material autonomy, and open new prospects for applications, both in aerospace and beyond.” Julie Vaudour, Deputy Director of R&D at Daher.

Source: Daher