Circular economy and sustainability
RECYCLING ARAMID FABRICS FROM BALLISTIC VIA GREEN SPINNING FOR SUSTAINABLE MATERIALS RECOVERY
REGEN
Motivation
The growing demand for defense equipment highlights the need for Europe to secure its supply chains. As the geopolitical environment continues to evolve, it is essential for Europe to explore options such as recycling and other circular solutions, emphasizing that self-sufficiency in raw materials is key.
Bulletproof vests represent a multilayer defense system designed to protect soldiers from a range of ballistic threats. One of the main layers of these vests is made of aramids, which are advanced materials widely used for their properties that contribute to the effectiveness of personal protection.
The service life of a bulletproof vest depends on several factors, including the materials used and the conditions under which it is worn. The typical lifespan is up to 10 years under normal conditions. However, exposure to ultraviolet light, humidity, and extreme temperatures can degrade the fibers, reducing their effectiveness. As a result, large amounts of waste are generated annually from these products, which is why a sustainable and efficient solution is sought to enable a circular economy and the development of new products from recycled materials.
Objectives
The REGEN project aims to advance maturity and demonstrate the technical and economic feasibility of recycling discarded protective vests made of aramid. In this way, REGEN seeks to take real waste from end-of-life bulletproof vests and recycle the aramid soft component of the vest, converting the woven material into a continuous fiber spool that can be processed and used for the remanufacturing of new bulletproof vests.
Expected results
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Coating removal: study their impact on dissolution and develop chemical or physical methods for their elimination.
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Spinning optimization: adjust parameters to produce high-quality fibers for yarns.
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Filament production: generate suitable filaments from recycled fiber.
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High-quality hybrid fabrics: combine virgin and recycled fibers; perform physical and mechanical testing.
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Ballistic testing: integrate recycled yarns into hybrid armors and evaluate performance according to current standards.
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Life Cycle Assessment (LCA): assess the environmental sustainability of the process in accordance with ISO 14040-44.
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Techno-economic assessment (TEA): analyze recycling and manufacturing costs to determine the minimum selling price (MSP).
Grant number: 02 – 24.ISE.CP.140
Programme: 24.ISE.CP.140 — Proofs of Concept Aimed at Enhancing Circularity in Defence Applications
Period of execution: April 2025 – March 2026
Status: In progress
Entity: European Defence Agency
This project has received funding from the European Union’s European Defence Fund programme. The contents and opinions expressed are the sole responsibility of the author(s) and can in no way be taken to reflect the views of the European Union or the European Defence Agency. Neither the European Union nor the European Defence Agency can be held responsible for them.
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R&D AREAS
New high-performance functionalised materials
Circular economy and sustainability
Advanced manufacturing, smart textiles and digitalisation
High value-added solutions for strategic markets
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