University of Birmingham and Gen 2 Carbon Limited KTP 24_25 R4

A factory in the UK will turn recycled carbon fibre into the gas diffusion layers that sit at the heart of hydrogen fuel cells and water electrolysers. These thin, porous sheets are critical components: they let hydrogen gas reach the catalyst while allowing water and electrons to pass through. Currently, most are made from virgin carbon fibre, a material that is energy-intensive to produce and expensive. The project aims to replace that virgin feedstock with recycled carbon fibre from end-of-life aerospace and automotive parts, creating a circular UK supply chain for the material. If the technology works at commercial scale, it could lower the cost of electrolysers and fuel cells—key devices for producing and using green hydrogen. That matters for decarbonising heavy transport, industrial heating, and grid-scale energy storage. It also reduces waste and keeps valuable carbon fibre out of landfill. The project is applied engineering: it tests whether recycled fibre can match the performance of virgin material in real manufacturing conditions, and whether the economics stack up for high-volume production.