From Pond to Propeller: Algae-Based Carbon Fiber Powers Airbus Aviation Test

Algae-derived carbon fiber by TUM used by Airbus

Could the future of aviation be grown in a bioreactor? In a remarkable step toward sustainable aerospace manufacturing, scientists at the Technical University of Munich (TUM) have developed a new method to convert microalgae into high-performance carbon fiber. The innovation, part of the GreenCarbon project, eliminates fossil fuel dependency from the production of acrylonitrile—the precursor to carbon fiber—using photosynthetically active algae as the raw feedstock.

This process not only reduces the carbon footprint of advanced composite materials, but also introduces a potential carbon-negative pathway by absorbing CO₂ through algae cultivation. The material has already been successfully flight-tested by Airbus, marking a milestone in green engineering.

Photosynthesis Meets Performance Engineering

Traditionally, acrylonitrile—the key molecule used in carbon fiber production—is derived from petroleum-based propylene. In contrast, the TUM-led team used photosynthetic algae to absorb atmospheric CO₂, producing energy-rich oils that are then chemically transformed into glycerol and ultimately acrylonitrile. This technique turns algae into a renewable carbon source, cutting fossil inputs and creating a closed-loop system with reduced environmental impact.

Partnering with Fraunhofer IGB, the team scaled up this lab-based conversion method and collaborated with German company SGL Carbon to spin the bio-based acrylonitrile into heavy-tow carbon fibers. These fibers, consisting of 50,000 individual filaments each, were then laminated into carbon fiber-reinforced plastics ready for real-world use.

Airbus Takes It to the Sky

After thorough life-cycle assessments and performance evaluations, Airbus fabricated aircraft components using this algae-derived carbon fiber. In 2024, those parts were used in a test flight of a research helicopter, showing that bio-based composites can match the mechanical performance of conventional petroleum-derived carbon fiber.

This milestone test not only validated the material’s real-world viability but also signaled a new frontier in sustainable aerospace and lightweight engineering.

Beyond Aviation: Broader Applications and Impact

While the focus is currently on aerospace, the potential applications of algae-based carbon fiber extend far beyond. Industries such as automotive, wind energy, and sports equipment could all benefit from a lighter, cleaner carbon fiber alternative. Crucially, the GreenCarbon materials meet existing industrial standards, meaning manufacturers can integrate them without overhauling their production systems.

According to Prof. Thomas Brück, coordinator of the GreenCarbon project at TUM, “Our GreenCarbon value chain opens up new pathways for replacing fossil feedstocks across the chemical industry.”

Scaling the Solution

Now that the concept is proven, the consortium aims to secure renewed funding from the German Federal Ministry of Research, Technology, and Space (BMFTR) to optimize cost-efficiency and bring the process to industrial scale. Further research is also underway to adapt this algae-derived carbon pathway for other essential chemicals, including acrylic acid, a key monomer in many polymers.

When paired with renewable energy sources, the algae-to-carbon fiber pipeline offers a blueprint for carbon-negative materials production—a rare but critical innovation in the push for climate-neutral manufacturing.

To read the full article, visit: Interesting Engineering – Algae-based carbon fiber takes flight in Airbus test.

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