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Gen 2 Carbon, Americarb launch rCF strategy for clean energy

Combined expertise unlocks novel applications for rCF in batteries, fuel cells, electrolyzers and structural energy storage.

Grace Nehls
Edited by:  Grace Nehls
Senior Managing Editor, ÂÌñÏ×ÆÞ and Products Finishing

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Gen 2 Carbon (Coseley, U.K.) and  (Niagara Falls, N.Y., U.S.) have announced a strategic partnership to accelerate the development and commercialization of recycled carbon fiber (rCF) materials for clean energy technologies. This cross-Atlantic collaboration aims to transform waste carbon fiber into high-performance products that directly support the global transition to a circular, net-zero economy.

Gen 2 Carbon specializes in collecting, recycling and converting carbon fiber-reinforced polymer (CFRP) waste into high-quality nonwoven intermediates and recycled fibers. Americarb’s capabilities lie in fiber impregnation, curing and heat treatment to produce engineered products — including electrodes, gas diffusion layers and bipolar plates — for advanced energy storage and conversion. Together, the companies will repurpose difficult-to-recycle CFRP waste into advanced components and establish a fully integrated supply chain for rCF-based products, reducing reliance on virgin carbon fiber and lowering raw material costs and carbon footprint.

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The partnership will deliver integrated solutions for clean energy sector needs, targeting:

  • Lithium-ion batteries (rCF as a cost-effective, partial replacement for synthetic graphite anodes)
  • Flow and metal-air batteries (rCF felts as high-performance, freestanding electrodes)
  • Fuel cells and electrolyzers (rCF nonwovens and composites for efficient gas diffusion layers and dense bipolar plates)
  • Structural power (multifunctional rCF composites capable of storing energy while bearing mechanical loads).

According to Gen 2 Carbon and Americarb, commercial users — including battery, fuel cell and electrolyzer manufacturers — will benefit from 20-30% cost savings compared to virgin fiber alternatives; matching or exceeding performance in demanding energy applications; up to 95% lower carbon footprint (based on life cycle analysis); and enhanced supply chain resilience by leveraging abundant domestic CFRP waste.

This approach also targets the acceleration of green hydrogen deployment and adoption, transportation electrification, renewables integration into modern grids and circular economy practices that turn industry waste into strategic resources.

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