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Scaling sustainable carbon fibre production: A breakthrough in lignin-based innovation

Mon, 24 Mar 2025 09:50:00 +0000

Carbon fibre is a critical material for industries such as aerospace and automotive, prized for its strength and lightweight properties. However, traditional carbon fibre production relies on costly, petroleum-based materials, driving up costs and environmental impact.

Lignin – a widely available by-product of cellulose production, with around 70 million tonnes generated annually – offers a promising, sustainable alternative. Typically treated as waste or burned for energy, lignin has untapped potential for high-value applications, including next-generation carbon fibre manufacturing.

From lab to pilot scale

Industry partner Lixea has been collaborating with Imperial College London, where Dr Agi Brandt-Talbot and Professor Milo Shaffer developed a patented technology to convert lignin into carbon fibre at a small lab scale (1ml production). The process leveraged two key innovations:

Ionic liquid technology – dissolving various lignins while allowing the liquid to be recycled after fibre formation.
Polyvinyl alcohol (PVA) – a non-toxic, biodegradable polymer used as a spinning aid.

This approach not only enables the production of high-lignin-content fibres (75-90%) with excellent structure and yield but also significantly reduces costs. By replacing petroleum-based precursors with lignin and ionic liquids – both renewable, lower-cost, and less toxic materials – production costs could be reduced.

Ұ��’s ability to scale up

To validate this technology at scale, Dr Joanne Ng from Imperial College joined forces with Drs Dominic Wales and Umar Muhammad, researchers at The University of Ұ�� and Royce Application Scientists, led by . Together the team created a pilot-scale demonstration at the Fibre Technology Platform, at the Henry Royce Institute, using its wet spinning line. Lignin was sourced from Lixea’s pilot plant, which uses the same ionic liquid to extract lignin from wood waste, ensuring process alignment with the company’s existing technologies.

The team tested three different lignins – two from spruce sawdust, and one from bagasse, a by-product of sugar production – with the bagasse-derived lignin proving most effective, enabling continuous fibre spinning at pilot scale for the first time.

Key learning and future development

Several critical insights emerged from the trials. Firstly, drying control was crucial to prevent fibre shrinkage. Secondly, lignin solutions became more viscous over time, requiring adjustments to maintain quality. And thirdly, spinneret design affected fibre uniformity, highlighting the need for further refinement and development of the facility.

Through the project the team successfully produced continuous fibres. The next steps include refining fibre drying, collection, and carbonisation processes, which will be essential for scaling up this breakthrough technology in the UK.

A milestone for sustainable carbon fibre

Ұ��’s success in scaling up this novel technology marks a significant step toward commercially viable, sustainable carbon fibre production.

The future of carbon fibre innovation

With continued advancements and industry collaboration, lignin-based carbon fibre could soon become a commercially scalable, high-performance, and environmentally friendly alternative to petroleum-derived materials. Ұ��’s pioneering role in technology scale-up reinforces its position as a leader in materials innovation and sustainable manufacturing, helping new ideas emerging in other UK leading universities, such as Imperial, make real-world impact.

Meet the researcher

Jonny Blaker, Professor in Biomaterials, principle research areas are i) Bio-inspired hierarchical composite materials and ii) Advanced materials derived from synthetic biology, with an emphasis on medical applications. He currently leads projects on bioactive medical materials, mask-less digital photolithography for 3D printing/patterning surfaces, development of bio-inks for 3D printing/biofabrication, the exploitation surfaces and interfaces for materials production, processing of fibres, especially nanofibres via solution blow spinning including silks derived from synthetic biology, as well as shape-morphing composites.

University awarded £30 million to train the next generation of science and engineering researchers through four new Centres for Doctoral Training

Tue, 12 Mar 2024 15:00:00 +0000

Four Centres for Doctoral Training (CDT) will train more than 350 doctoral students after being awarded over £30m funding.
The CDTs will support in developing the UK’s skills base in critical technologies by training students to tackle key challenges such as meeting net-zero targets through advanced materials, nuclear energy, robotics and AI.
Ұ�� is in the top three most-awarded institutions for CDTs after University of Bristol and University College London, and equal to University of Edinburgh.

The University of Ұ�� has been awarded £30 million funding by the Engineering and Physical Sciences Research Council (EPSRC) for four Centres for Doctoral Training as part of the UK Research and Innovation’s (UKRI) £500 million investment in engineering and physical sciences doctoral skills across the UK.

Building on Ұ��’s long-standing record of sustained support for doctoral training, the new CDTs will boost UK expertise in critical areas such as advanced materials, AI, and nuclear energy.

The CDTs include:

EPSRC Centre for Doctoral Training in 2D Materials of Tomorrow (2DMoT) - with cross-disciplinary research in the science and applications of two-dimensional materials, this CDT will focus on a new class of advanced materials with potential to transform modern technologies, from clean energy to quantum engineering. Led by , Professor of Physics at The University of Ұ��.
EPSRC Centre for Doctoral Training Developing National Capability for Materials 4.0 - this CDT will bring together students from a range of backgrounds in science and engineering to drive forward the digitalisation of materials research and innovation. Led by , Professor of Applied Mathematics at The University of Ұ�� and the Henry Royce Institute.
EPSRC Centre for Doctoral Training in Robotics and AI for Net Zero - this CDT will train and develop the next generation of multi-disciplinary robotic systems engineers to help revolutionise lifecycle asset management, in support of the UK’s Net Zero Strategy. Led by , Reader in the Department of Electrical and Electronic Engineering at The University of Ұ��.
EPSRC Centre for Doctoral Training in SATURN (Skills And Training Underpinning a Renaissance in Nuclear) - the primary aim of SATURN is to provide high quality research training in science and engineering, underpinning nuclear fission technology. Led by , Professor of Nuclear Chemistry at The University of Ұ��.

Ұ�� received joint-third most awards across UK academia, and will partner with University of Cambridge, University of Glasgow, Imperial College London, Lancaster University, University of Leeds, University of Liverpool, University of Oxford, University of Sheffield, University of Strathclyde and the National Physical Laboratory to prepare the next generation of researchers, specialists and industry experts across a wide range of sectors and industries.

In addition to leading these four CDTs, The University of Ұ�� is also collaborating as a partner institution on the following CDTs:

EPSRC Centre for Doctoral Training in Fusion Power, based at University of York.
EPSRC Centre for Doctoral Training in Aerosol Science: Harnessing Aerosol Science for Improved Security, Resilience and Global Health, based at University of Bristol.
EPSRC Centre for Doctoral Training in Compound Semiconductor Manufacturing, based at Cardiff University.

Along with institutional partnerships, all CDTs work with industrial partners, offering opportunities for students to develop their skills and knowledge in real-world environments which will produce a pipeline of highly skilled researchers ready to enter industry and take on sector challenges.

Professor Scott Heath, Associate Dean for Postgraduate and Early Career Researchers at The University of Ұ�� said of the awards: “We are delighted that the EPSRC have awarded this funding to establish these CDTs and expose new cohorts to the interdisciplinary experience that researching through a CDT encourages. By equipping the next generation of researchers with the expertise and skills necessary to tackle complex issues, we are laying the groundwork for transformative solutions that will shape industries and societies for generations to come.”

Announced by Science, Innovation and Technology Secretary Michelle Donelan, this round of funding is the largest investment in engineering and physical sciences doctoral skills to-date, totalling more than £1 billion. Science and Technology Secretary, Michelle Donelan, said: “As innovators across the world break new ground faster than ever, it is vital that government, business and academia invests in ambitious UK talent, giving them the tools to pioneer new discoveries that benefit all our lives while creating new jobs and growing the economy.

“By targeting critical technologies including artificial intelligence and future telecoms, we are supporting world class universities across the UK to build the skills base we need to unleash the potential of future tech and maintain our country’s reputation as a hub of cutting-edge research and development.”

These CDTs join the already announced . This CDT led by , Senior Lecturer in Machine Learning at The University of Ұ��, will train the next generation of AI researchers to develop AI methods designed to accelerate new scientific discoveries – specifically in the fields of astronomy, engineering biology and material science.

The first cohort of AI CDT, SATURN CDT and Developing National Capability for Materials 4.0 CDT students will start in the 2024/2025 academic year, recruitment for which will begin shortly. 2DMoT CDT and RAINZ CDT will have their first cohort in 2025/26.

For more information about the University of Ұ��'s Centres for Doctoral Training, please visit:

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