Thermoplastic composites for sports innovation

TPCs are plastics reinforced with fibres, such as glass or carbon fibres. These fibres give the material its strength. And because it is thermoplastic, the material can be recycled and reused. The discarded plastic is heated and mechanically recycled into reusable material. This makes TPCs ideal for applications where weight, strength, and sustainability matter.

TPCs are already widely used in the automotive industry (pdf, 108 kB). The aerospace sector also benefits from TPCs, and closer to home, they are used in household appliances. But they are also gaining ground in sports products: from hockey sticks to skis and protective gear. And it is precisely in this area that opportunities for circular innovation arise.

How to make recycled desirable again?

Many sports brands want to become more sustainable. And they are open to recycled materials, but they face three major questions:

1. How do you maintain the quality of recycled TPC?
2. How do you ensure recycled TPC remains consistent in quality?
3. How do you scale up and ensure a reliable supply of recycled material?

Richard Janssen, Business Development Manager at TNO, spoke with many parties in the TPC industry. His conclusion was clear: 'Everyone wants to go circular, but there are hardly any recycling chains for TPCs that can deliver reliable material. It’s a chicken-and-egg situation: potential recycling chains are waiting for market demand, and brand companies are waiting for the availability of recycled material. Initiatives will need to be taken to jointly build these new chains.'

The solution: high-quality recycling and collaboration

TNO has developed an innovative method to recycle TPCs in such a way that the fibres break as little as possible. As a result, the strength is largely retained. And that opens the door to high-end applications, even in sports products where performance and appearance are crucial.

We collaborate with companies in projects such as NXTGEN Hightech, where we recycle dozens of kilos of TPC per hour. And we help companies reuse those recycled materials in their own products or those of others, while maintaining quality and appearance.

Ready for the next step?

Whether you are a manufacturer of sports products, a brand looking to innovate circularly, or a material supplier, we offer:

• Access to the latest recycling technologies for TPCs
• Support in product development using recycled material
• Testing and validation facilities to demonstrate performance
• An international network of partners, knowledge institutions, and manufacturers

The sports and leisure industry is on the brink of a circular revolution. TPCs can play a key role in this and TNO helps you take that step, from ambition to action.

Want to know how your products can become stronger, lighter, and more sustainable? Richard Janssen is can tell you more about the possibilities.