From Superjumbo to Single-Aisle: Airbus Consortium Proves “Closed-Loop” Composite Recycling is Flight-Ready

In a significant step toward a circular aviation economy, a consortium led by Airbus has successfully demonstrated that high-value thermoplastic composite parts can be recycled from retired aircraft and repurposed into structural components for new jets. The project, titled “Recycled and Ready,” involved taking an end-of-life part from a retired A380 and manufacturing it into a flight-ready component for an A320neo.

According to the official announcement released on January 15, 2026, the initiative proves that aerospace composites, historically difficult to recycle without degrading their quality, can be retained within the aviation supply chain rather than being “downcycled” into lower-value products like filler or ground transport components.

The breakthrough was achieved through a partnership between Airbus, materials supplier Toray Advanced Composites, aerostructures manufacturer Daher, and dismantling specialist Tarmac Aerosave. The team’s efforts were recognized with a JEC Innovation Award in the “Circularity and Recycling” category.

Closing the Loop: The Process

The core achievement of the project was the successful conversion of a used engine pylon fairing cover (cowl) from a dismantled A380 into a structural panel for an A320neo pylon. This transition from a “superjumbo” part to a single-aisle component validates the industrial feasibility of reusing thermoplastic materials.

The project relied on the specific properties of the material used: Toray Cetex® TC1100, a carbon fiber reinforced Polyphenylene Sulfide (PPS) thermoplastic. Unlike traditional thermoset composites, which undergo a chemical change during curing that cannot be reversed, thermoplastics can be melted, reshaped, and reformed multiple times.

Consortium Roles

The project required precise coordination across the supply-chain, with each partner fulfilling a specific role:

• Tarmac Aerosave: Managed the dismantling of the A380, developing a non-destructive process to recover the composite parts without compromising the material’s integrity.
• Toray Advanced Composites: Assessed the quality of the recovered material to ensure it met the stringent safety standards required for a “second life” in structural aerospace applications.
• Daher: Led the industrial manufacturing process, reshaping the recovered material into the new A320neo component.
• Airbus: Served as the project integrator, overseeing technical requirements and managing the certification of the recycled part for flight testing.

Industry Significance and Executive Commentary

This development addresses one of the aviation industry’s most persistent sustainability challenges: the disposal of carbon fiber composites. While metals like aluminum and titanium have recovery rates near 90%, composites have often ended up in landfills because separating the fibers from the resin is technically difficult and expensive.

Isabell Gradert, Airbus VP of Central Research and Technology, emphasized the importance of cross-industry collaboration in achieving this milestone:

“This recognition from the JEC shows how complex challenges, including high-value recycling, are best tackled through partnership. We exist in a complex aerospace supply chain in a hyper-connected world. If a company comes up with a solution on its own, that’s a great story. If an entire industry does it together, that’s transformative.”

, Isabell Gradert, Airbus VP Central Research and Technology

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Scott Unger, CEO of Toray Advanced Composites, noted that the project opens the door for high-performance materials to be “meaningfully reused and reintegrated” into structural applications, rather than being discarded.

AirPro News Analysis

The Shift to Thermoplastics: This project underscores the strategic advantage of thermoplastic composites over traditional thermosets. While thermosets (like those used heavily on the Boeing 787 and early A350s) offer excellent strength-to-weight ratios, they are chemically “baked” and difficult to recycle. The success of the “Recycled and Ready” program suggests that future aircraft designs may increasingly favor thermoplastics to ensure end-of-life recyclability.

Supply Chain Resilience: Beyond sustainability, this approach offers a strategic benefit. By treating retired aircraft as “material mines,” manufacturers can reduce their dependence on virgin raw materials. With over 10,000 thermoplastic parts on a single A380, the potential inventory for recycled feedstock is substantial. This could help insulate manufacturers from price volatility and supply chain disruptions in the global carbon fiber market.

Frequently Asked Questions

What is the difference between thermoset and thermoplastic composites?

Thermoset composites are cured irreversibly, meaning they cannot be melted down and reshaped. Thermoplastic composites, like the PPS used in this project, can be heated, reshaped, and cooled multiple times without significant loss of mechanical properties.

What aircraft were involved in this test?

The source material came from a retired Airbus A380, and the recycled part was manufactured for an Airbus A320neo.

Who were the partners in the consortium?

The project was a collaboration between Airbus, Toray Advanced Composites, Daher, and Tarmac Aerosave.

Sources

• Airbus