Recycled Carbon Fibers in Bulk Molding Compounds: Influence of Recovery Route on Mechanical and Economic Performance

ABSTRACT Recycling routes influence both the quality of recovered carbon fibers and the environmental and economic value of reusing them. This study examines bulk molding compound composites produced with fibers sourced from post‐industrial waste, pyrolysis, and low temperature solvolysis. Fiber quality was evaluated using microscopy and thermal analysis, and composite performance was measured through tensile, flexural, and shear tests. Post‐industrial waste fibers showed the highest retention of mechanical properties, with flexural strength near 155 MPa, indicating minimal degradation. Pyrolyzed fibers lost tensile strength but still provided reasonable flexural and shear behavior, while solvolyzed fibers showed intermediate performance influenced by surface residues. A techno economic model, combined with a new cost benefit metric and two‐dimensional sensitivity maps, was used to assess how plant capacity and recovery efficiency affect viability. The maps indicate that post‐industrial waste offers stable performance at low cost with immediate environmental gains. Pyrolysis becomes cost effective at moderate production scale, while solvolysis is difficult to justify unless both recovery and plant size are high. Overall, the results demonstrate the environmental and industrial value of high quality recycled fibers and provide a practical basis for selecting sustainable recycling routes.