Net zero carbon fibre: Practical pathways for the wind sector’s toughest material
Carbon fibre plays a critical role in wind turbine performance. It delivers strength, stiffness and weight savings - yet comes with high embodied carbon.
Around 12% of a blade’s mass can contribute nearly 50% of its lifetime footprint.
This report sets out clear, evidence-based options to reduce that impact. It focuses on what manufacturers can act on today, what’s emerging across the 2030s, and where supply chains can shape outcomes over time.
What this report delivers
Drawing on lifecycle analysis, commercial data and process energy modelling, the paper outlines realistic, high-impact steps that carbon fibre producers and users can take - even before new fuels or technologies are widely available.
Rather than chasing single solutions, it lays out a multi-horizon strategy, showing how current decisions shape future outcomes. The focus is on technology readiness, emissions impact, and energy control.
Funded by the SusWIND programme, this report is designed as a companion to the first paper in this series, Drop-in Decarbonisation Solutions.
Key insights at a glance
- Electrification is the fastest route to progress: Replacing gas with electricity for oxidation and carbonisation processes addresses more than 70% of energy use. It reduces exposure to fuel volatility and accelerates emissions savings.
- Green fuels carry promise, with caveats: e-Methane and hydrogen offer long-term options, though cost, infrastructure and delivery times remain uncertain. These should complement, not delay, near-term action.
- Exhaust treatment remains the hardest challenge: Current abatement systems require very high temperatures and contribute over a quarter of total energy use. New electrified solutions are in development and need industry focus.
- Efficiency matters from day one: Heat recovery and lower-power heating approaches all deliver early benefits - both environmentally and commercially.
- Energy strategy needs active choices: Securing REGOs or investing in on-site renewables gives manufacturers more control over their transition and supports progress ahead of grid-scale change.
A stepwise plan - designed for delivery
The report outlines a practical roadmap to 2050, aligned with grid evolution, technology maturity and operational constraints.
- 2025–2030: Prioritise process electrification, switch to bio-based feedstocks, adopt energy-saving systems, and support green gas development.
- 2030–2040: Deploy emerging electrified abatement solutions and continue replacing legacy systems.
- 2040 onwards: Transition to advanced low-carbon heating, full electrification, and high-efficiency site design.
Each stage includes actions that manufacturers can control, procure or influence directly.
Who it's for
- Carbon fibre and PAN (polyacrylonitrile) fibre producers
- Wind energy manufacturers and design engineers
- Sustainability and decarbonisation leads
- Policy, funding and infrastructure decision-makers
The findings provide a framework for action - aligning operational, technical and environmental priorities over time.
To support developments in carbon fibre, NCC and CPI are working together to strengthen innovation capabilities that are essential to the UK's supply and manufacture of advanced materials. Specifically, the focus is to develop sovereign capability for the production of novel carbon fibre formulations and processing techniques, which will, ultimately, support tangible advances in performance, cost and sustainability.
Read the second in a two-part series on decarbonising carbon fibre for the wind sector.
SusWIND is a joint industry programme by NCC in partnership with the Offshore Renewable Energy Catapult, focused on advancing a circular economy for large structure composites by driving innovation in recycling and sustainable supply chains.