This document presents a system for producing disposable carbon fiber formworks using an algorithmic design and robotic fabrication process. Laboratory tests showed that concrete samples cast in formworks produced with this system achieved compressive strengths almost three times greater than samples without formworks. The system was developed by Indexlab at Politecnico di Milano in collaboration with Carmon@carbon.

1. 24 Compositi
cations, aiming to develop highly func-
tional products and exploring new aes-
thetics. We build prototypes of com-
plex shapes through the application of
cutting-edge technology using natu-
ral materials, metals, polymers, ce-
ment-based materials and compos-
ites. INDEXLAB is a cross-discipli-
nary research environment that offers
a range of services to architecture and
engineering firms and manufacturing
companies, such as computational
design, digital and robotic fabrication,
simulation, interaction and media de-
sign. www.indexlab.it
This research has been conducted by
Pierpaolo Ruttico and Massimo Rota
(Indexlab – Politecnico di Milano), in
collaboration with Federico Carmona
(Carmon@carbon).
All the mentioned figures refer
to the Italian version
Fig. 1: Algorithmic design of the formwork Fig. 2: Al-
gorithmic programming of the robot Fig. 3: Cutting the
mold using a hot wire Fig. 4: Filament winding of the
mold and CFRP curing process Fig. 5: Return of the form-
work, ready for the concrete casting Fig. 6: Results of
tests of ultimate resistance to uniaxial compression
Laboratory tests show that – in terms
of cross-section – a concrete sample –
with a disposable formwork made with
this system – offers a final compres-
sive strength almost three times great-
er than a naked sample (97 tons com-
pared to 36 tons).
Indexlab
INDEXLAB is a research lab at the Po-
litecnico di Milano focused on the de-
velopment of innovative construction
systems for the building construction
industry. We experiment with new
manufacturing processes and appli-
- Development of a system for the production of disposable carbon fiber formworks -
24 Compositi
Wind Energy provided 14% of the EU’s electricity and account-
ed for 49% of all the new power generation capacity in Europe
in 2018.
Composites enable both performance and sustainability of wind
energy by allowing lighter and longer blades, optimizing conver-
sion efficiency and increasing turbine power output.
More than 70,000 wind turbines are spinning in Europe with a
combined capacity of 189 GW and an estimated composite ma-
terial inventory of more than 2.5 million tons.
42,000 wind turbines are expected to be decommissioned in
the very next years based on approximately 20-25 years lifetime
and on the replacement of old models with newer and more ef-
ficient models.
The European Chemical Industry Council (Cefic), through its Sec-
tor Group Unsaturated Polyester Resins (AOC Aliancys, Ashland,
Polynt and Scott Bader) and some partners, have launched a pro-
ject to provide an overview of the different, innovative Compos-
ites recycling technologies relevant for wind turbines.
It is our goal to supply relevant and practical information on the
subject, promote the sustainable management of composite
blade waste and help increase the circularity of Fiber Glass Re-
inforced wind turbine blades.
POLYNT GROUP
Learnings from wind turbine recycling will then be transferred
to the other multiple applications and markets in Europe in or-
der to enhance overall composites sustainability.
Glass Reinforced Composites recycling technologies currently
exist at different degrees of commercialization:
• Mechanical recycling: use of regrind fiber and filler in new
composite components – Commercial at small scale
• Solvolysis into original raw materials – Under development
• Co-processing in cement kilns – Commercial at Industrial
scale and economically viable at present.
Co-processing in cement kilns allows partial replacement of coal
and cement raw materials by glass-reinforced composites, of-
fers significant CO2 emission reduction and early studies indi-
cate positive LCA effect.
Composites recycling through co-processing is fully compliant
with Waste Framework Directive 2008/98/EC.
Next Steps will involve the following activities:
• Strengthen collaboration with relevant stakeholders in order
to develop a joint approach for Composites Recycling as an
integral part of the life cycle of wind turbines.
• Generate a more in-depth analysis and comparison between
the technologies, with specific End-of-Use scenarios.
• Investigate how to effectively collect and combine waste
streams for reducing collection/ logistic cost and further in-
dustrialization of recycling processes.
Composite Wind Blade Sustainability