August 2025 Composites Blog
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August 4, 2025
Renewable Carbon Fiber Production From Microalgae
Renewable Carbon Fiber Production From Microalgae
The GreenCarbon project, coordinated by Prof. Thomas Brück at TUM’s Chair of Synthetic Biotechnology, brings together Fraunhofer IGB, SGL Carbon, and Airbus to develop carbon fibers from renewable sources. The process begins with oils extracted from photosynthetic microalgae, which naturally capture atmospheric CO2. These oils are then chemically processed to extract glycerine, which is catalytically converted into acrylonitrile—the essential precursor for carbon fiber production. Fraunhofer IGB has successfully refined this conversion at laboratory scale, preparing it for the next stage: industrial application.
SGL Carbon produced 50k heavy-tow carbon fibers, each bundle containing 50,000 individual filaments, adhering to recognized industry standards. These fibers were then used to create carbon fiber-reinforced plastics, known as composite laminates, which demonstrate the same high-performance properties as conventional materials. Airbus contributed by performing life-cycle assessments and evaluating the technology for aviation applications. In 2024, a research helicopter featuring renewable carbon fibers completed its maiden flight, confirming the suitability of these materials for aerospace use.
Looking ahead, the consortium plans to optimize the process and expand it to industrial production. The approach could also support the sustainable manufacture of other polymers, including acrylic acid, which is currently derived from fossil feedstocks. Prof. Brück emphasizes that the GreenCarbon value chain opens new pathways for renewable, high-performance materials, combining environmental benefits with advanced material properties. Learn more about this topic here.
SGL Carbon produced 50k heavy-tow carbon fibers, each bundle containing 50,000 individual filaments, adhering to recognized industry standards. These fibers were then used to create carbon fiber-reinforced plastics, known as composite laminates, which demonstrate the same high-performance properties as conventional materials. Airbus contributed by performing life-cycle assessments and evaluating the technology for aviation applications. In 2024, a research helicopter featuring renewable carbon fibers completed its maiden flight, confirming the suitability of these materials for aerospace use.
Looking ahead, the consortium plans to optimize the process and expand it to industrial production. The approach could also support the sustainable manufacture of other polymers, including acrylic acid, which is currently derived from fossil feedstocks. Prof. Brück emphasizes that the GreenCarbon value chain opens new pathways for renewable, high-performance materials, combining environmental benefits with advanced material properties. Learn more about this topic here.
