On May 20, 2026, Japan’s New Energy and Industrial Technology Development Organization (NEDO) announced the launch of a new research and development initiative aimed at recycling carbon fiber reinforced plastic (CFRP) from retired aircraft. The project—provisionally referred to here as the Next-Generation Aircraft Recycling Industry Development Project—seeks to establish a supply chain that recovers CFRP from decommissioned aircraft and returns it for use in new aircraft, with the goal of achieving practical aircraft-to-aircraft recycling by fiscal 2030.

The Challenges of Recycling CFRP

CFRP is widely used in aircraft because its exceptional combination of light weight and high strength helps improve fuel efficiency while reducing CO₂ emissions through lighter airframe structures. In aircraft such as the Boeing 787 and Airbus A350 XWB, CFRP accounts for approximately 50% of the structural weight. As many of these CFRP-intensive aircraft are expected to reach the end of their service lives between 2030 and 2045, the volume of end-of-life CFRP requiring disposal is projected to increase significantly.

CFRP consists of carbon fiber (CF) embedded in a resin matrix. Because the two materials are difficult to separate, most end-of-life CFRP is currently disposed of in landfills rather than recycled. Even when carbon fiber is recovered, it is typically reduced to short fibers, making it difficult to achieve the same level of performance as virgin carbon fiber. This has been one of the key barriers to wider adoption of CFRP recycling.

Establishing an Aircraft-to-Aircraft Recycling Process

Building on the preliminary research project, Research on Continuous-Fiber Technology for Recycled Carbon Fiber and Its Application to Aircraft (FY2023–FY2025), NEDO developed a technology that thermally treats CFRP waste, separates it into thin layers, and uses localized laser heating to remove residual resin while recovering carbon fibers above a specified length. Tests confirmed that the recovered fibers achieved tensile strength comparable to that of virgin carbon fiber, demonstrating the successful recovery of continuous fibers suitable for aircraft applications.

The new project aims to scale up this technology by establishing an integrated, end-to-end recycling process covering every stage—from aircraft dismantling and component cutting to carbon fiber recovery, regeneration, and reuse. Development efforts will focus on technologies for efficiently recovering CFRP from retired aircraft, environmentally responsible carbon fiber recovery and regeneration processes, and manufacturing processes that convert recycled carbon fiber into feedstock materials. The project will also evaluate the mechanical properties of the recycled materials, define technical requirements, and conduct demonstration testing using a test aircraft. Together, these activities aim to accelerate the application of recycled CFRP to secondary structural components and aircraft interior parts.

In addition, recycled carbon fiber (rCF) has been shown to generate lower CO₂ emissions during production than virgin carbon fiber. By establishing a closed-loop, aircraft-to-aircraft recycling process, the project is expected to support both decarbonization and the transition toward a circular economy.

Carbon Fiber Recycling Moves Closer to Commercialization

Efforts to recycle CFRP are also accelerating beyond the aviation industry.

Obayashi Corporation and Toyota Motor Corporation have developed the Rikabo-crete method, which converts CFRP manufacturing offcuts into short fibers for use as concrete reinforcement. According to the companies, the regenerated fibers reduce CO₂ emissions during production to approximately one-fifteenth of those associated with virgin carbon fiber.

Toray Industries, meanwhile, has developed a proprietary recycling technology that uses a specially formulated decomposing agent to recover high-quality rCF from CFRP waste generated by aircraft, wind turbines, automobiles, and other applications while minimizing thermal damage. The company also supplies a nonwoven material that retains more than 95% of the tensile strength of petroleum-derived virgin carbon fiber.

While most current recycling initiatives repurpose recovered carbon fiber for applications outside the aerospace sector, NEDO’s project is distinguished by its goal of achieving closed-loop, aircraft-to-aircraft recycling. By connecting aircraft manufacturing with end-of-life material recovery, the initiative aims to establish a more circular supply chain for the aerospace industry.

The project is scheduled to run from FY2026 through FY2030, with a budget of ¥540 million for FY2026. Participating organizations include the Tokai National Higher Education and Research System, the Japan Fine Ceramics Center, Subaru Corporation, Jamco Corporation, and the Japan Aerospace Exploration Agency (JAXA).