Zero-waste, high-performance nonwovens
CAMX 2025: Through a reclaiming and reengineering process, Endeavor Composites creates nonwoven preforms from unused carbon fiber waste, reducing costs and environmental impact while still meeting stringent design requirements.
Share
Source | Endeavor Composites Inc.
(Knoxville, Tenn., U.S.) presents a patented nonwoven fiber technology that enables the production of defect-free, isotropic and multifunctional preforms without the need for binders. These factors result in stronger, more consistent products suitable for demanding applications across automotive, aerospace, industrial, defense, transportation, marine, and sports and leisure sectors.
High-performance nonwoven materials like carbon fiber have historically been cost-prohibitive or waste-intensive. Endeavor Composites aims to eliminate both barriers. The company optimizes manufacturing by reclaiming and reengineering unused, high-quality fiber remnants from fiber producers and recyclers. With its process, virtually zero materials go to landfill, the company reports, reducing costs and environmental impact for manufacturers while opening new revenue opportunities. On a broader scale, Endeavor Composites says its technology has the potential to monetize more than $1 billion annually in otherwise wasted carbon fiber.
Endeavor’s process delivers fabrics with high uniformity and strength, capable of processing fibers with aspect ratios up to 5200 (fiber-dependent). This opens the door to scalable, custom-engineered solutions that meet even stringent design requirements. Whether working with carbon fiber, metal, hemp, banana or other organic fibers, Endeavor collaborates closely with engineering, procurement and design teams to build tailored materials for next-gen applications.
At the core of its mission is application-driven R&D that empowers customers to overcome manufacturing bottlenecks and achieve previously unattainable performance benchmarks, carbon fiber being only the beginning of Endeavor Composites’ future work.
Related Content
-
JEC World 2024 highlights: Thermoplastic composites, CMC and novel processes
CW senior technical editor Ginger Gardiner discusses some of the developments and demonstrators shown at the industry’s largest composites exhibition and conference.
-
CirculinQ: Glass fiber, recycled plastic turn paving into climate solutions
Durable, modular paving system from recycled composite filters, collects, infiltrates stormwater to reduce flooding and recharge local aquifers.
-
Welding is not bonding
Discussion of the issues in our understanding of thermoplastic composite welded structures and certification of the latest materials and welding technologies for future airframes.
Related Content
JEC World 2024 highlights: Thermoplastic composites, CMC and novel processes
CW senior technical editor Ginger Gardiner discusses some of the developments and demonstrators shown at the industry’s largest composites exhibition and conference.
Read MoreCirculinQ: Glass fiber, recycled plastic turn paving into climate solutions
Durable, modular paving system from recycled composite filters, collects, infiltrates stormwater to reduce flooding and recharge local aquifers.
Read MoreWelding is not bonding
Discussion of the issues in our understanding of thermoplastic composite welded structures and certification of the latest materials and welding technologies for future airframes.
Read MoreInfinite Composites: Type V tanks for space, hydrogen, automotive and more
After a decade of proving its linerless, weight-saving composite tanks with NASA and more than 30 aerospace companies, this CryoSphere pioneer is scaling for growth in commercial space and sustainable transportation on Earth.
Read MoreRead Next
VIDEO: High-volume processing for fiberglass components
Cannon Ergos, a company specializing in high-ton presses and equipment for composites fabrication and plastics processing, displayed automotive and industrial components at CAMX 2024.
Read MoreAll-recycled, needle-punched nonwoven CFRP slashes carbon footprint of Formula 2 seat
Dallara and Tenowo collaborate to produce a race-ready Formula 2 seat using recycled carbon fiber, reducing CO2 emissions by 97.5% compared to virgin materials.
Read MoreComposites end markets: New space (2025)
Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.
Read More