Sustainable Recycling of EDM Wire Waste on Nylon Mesh in Carbon Fiber Composites for a Circular Economy
Vol. 27, No. 3, pp. 1517-1529,
Mar. 2026
10.1007/s12221-025-01299-z
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Abstract
This invention presents a new composite material made of waste electrical discharge machining (EDM) wire woven into a nylon mesh, which is then sandwiched between layers of carbon fiber. While recycling industrial waste to promote sustainability, the main goal is to improve mechanical properties including tensile strength, flexural strength, and impact resistance. Incorporating waste EDM wire into the nylon mesh greatly enhances load distribution and bonding strength inside the composite. Combined with epoxy resin and carbon fiber mats, the material has a tensile strength of 310 MPa, flexural strength of 152.94 MPa, and impact resistance of 10.5 Joule. X-ray diffraction (XRD) research demonstrates the presence of both crystalline (from nylon and metallic EDM wire) and amorphous (from carbon fiber) phases, indicating that all components are effectively integrated. FESEM and EDX examination shows a well-bonded microstructure with carbon fibers incorporated in the nylon matrix and trace metallic residues, indicating the composite’s structural integrity and wear resistance. These developments show significant increases over conventional carbon fiber composites, therefore stressing the efficacy of the reinforcement approach. The method also tackles important problems like delamination and low flexural strength usually seen in conventional composites by using waste materials, and the invention not only improves material performance but also helps environmental sustainability by supporting circular economy ideas. Its lightweight and robust character makes it especially appropriate for automotive, aerospace, and building sectors where cutting weight without sacrificing strength is critical by lowering raw material prices, the invention also offers an economically feasible manufacturing technique by means of thorough mechanical testing and validation, and the invention shows great promise for replacing more durable, less sustainable materials in high-performance applications. All things considered. This study makes a significant contribution toward creating high-strength composite materials that are environmentally friendly for advanced industrial applications.
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Cite this article
[IEEE Style]
G. Rajamurugan, R. Elayaraja, P. Krishnasamy, G. S. Sur, A. Paba, "Sustainable Recycling of EDM Wire Waste on Nylon Mesh in Carbon Fiber Composites for a Circular Economy," Fibers and Polymers, vol. 27, no. 3, pp. 1517-1529, 2026. DOI: 10.1007/s12221-025-01299-z.
[ACM Style]
G. Rajamurugan, R. Elayaraja, Prabu Krishnasamy, Gurtej Singh Sur, and Amod Paba. 2026. Sustainable Recycling of EDM Wire Waste on Nylon Mesh in Carbon Fiber Composites for a Circular Economy. Fibers and Polymers, 27, 3, (2026), 1517-1529. DOI: 10.1007/s12221-025-01299-z.