ICOMAT Establishes Factory II to Grow Composites Processing Capacity

Why It Matters

By industrializing up‑cycled TPC, Daher reduces reliance on virgin carbon fiber, cuts emissions, and opens new revenue streams across aerospace and additive‑manufacturing markets.

Key Takeaways

• 100% PPS scrap up‑cycled into carbon‑fiber pellets
• Pellets contain 56% carbon fiber, high mechanical performance
• Production capacity 4–8 metric tons annually
• 1.5 metric tons of pellets currently for sale
• New filament enables 3D printing of technical parts

Pulse Analysis

The aerospace and high‑performance engineering sectors are confronting mounting pressure to lower carbon footprints while maintaining stringent weight and strength requirements. Thermoplastic composites, especially carbon‑fiber‑reinforced polyphenylene sulfide (PPS), have emerged as a key material because they combine durability with recyclability. Yet the industry traditionally relies on virgin carbon fiber, which drives cost and environmental concerns. Up‑cycling initiatives that transform production scrap into reusable feedstock are therefore gaining traction, offering a pathway to circular economies and compliance with emerging sustainability regulations.

Daher’s Factory II operationalizes this circular model by grinding on‑site PPS scrap and re‑extruding it into pellets that retain 56 % carbon fiber content. With an annual capacity of 4–8 metric tons and 1.5 metric tons already marketed, the program demonstrates that large‑scale up‑cycling can be commercially viable. The company’s prior recognition at the 2026 JEC Innovation Awards underscores its technical credibility, while the integration of the Shap’in technology center ensures consistent material quality for injection‑molding and other high‑rate production processes. This move strengthens Daher's material autonomy and reduces dependence on external fiber suppliers.

The availability of up‑cycled PPS pellets and a dedicated 3D‑printing filament opens new design opportunities for both aerospace OEMs and downstream manufacturers. Additive manufacturing can now leverage recycled carbon‑fiber feedstock to produce complex, lightweight components without sacrificing performance, potentially accelerating part‑on‑demand strategies. Competitors are watching as Daher's model illustrates a scalable, profit‑generating approach to waste reduction. As regulatory frameworks tighten and customers demand greener supply chains, firms that embed circular material loops are likely to capture market share and achieve long‑term cost advantages.