CIDETEC Surface Engineering drives aerospace sustainability with a drone entirely manufactured from its 3R material

The recently completed RECICOM project has addressed the technical and environmental challenges associated with the use, repair, and recycling of composite materials in the aerospace sector, promoting solutions aligned with circular economy principles. One of its main innovations has been the manufacturing of a large drone using the 3R material patented by CIDETEC Surface Engineering, based on a thermoset epoxy resin with reversible chemistry. This formulation preserves the high mechanical performance required by the aerospace sector while introducing capabilities for repair, reuse, and recycling.

The use of composite materials in aviation represents a key solution to reduce weight, improve energy efficiency, and decrease CO₂ emissions. However, high costs and recycling difficulties have so far limited their expansion. With 3R prepregs reinforced with carbon fiber, CIDETEC offers a technical solution to these limitations, with a comprehensive approach that considers sustainability from design to end-of-life.

Among the main achievements of the project is the development of advanced hydrothermal processes for the recovery of carbon fiber from end-of-life thermoset composites, allowing its reintegration into new 3R materials. This strategy closes the life cycle of high-performance materials, minimizing waste and reducing operating costs.

Throughout the project, CIDETEC Surface Engineering has led the development of solutions in various key areas:

• Formulation of a 3R epoxy resin with reversible chemistry, maintaining 100% of its mechanical properties.
• Production of 3R prepregs reinforced with carbon fiber, used in the manufacturing of the demonstrator.
• Design of a manufacturing process for aerospace-grade composites from recycled fiber.
• Development of non-destructive inspection systems (NDI) based on acoustic emission, for real-time defect monitoring during manufacturing and service.
• Validation of repair processes for defects detected in 3R composites.
• Study of 3R material recycling, including performance analysis of second-generation recycled material.

RECICOM: Circular economy for the aviation of the future

The RECICOM project (Recycling and Composition of Composite Materials), coordinated by TITANIA and with the participation of FLUIDMECANICA SUR, DRONETOOLS, I-PUNTO END, and the University of Cádiz, was carried out between September 2022 and December 2024. With a total budget of €2,432,558, it received €1,647,864.88 in funding from the CDTI and was supported by the Ministry of Science and Innovation through the 2022 Aeronautical Technology Program, within the framework of the Recovery, Transformation and Resilience Plan.