Background Carbon fibre reinforced polymer (CFRP, or CF for carbon fibre) composites are increasingly used in several applications for their unique combination of low weight, strength and rigidity. The current market demand of some 38,000 tonnes/yr is expected to double by 2014. Using CFRP composites in structural parts to replace metals has many advantages, such as weight reductions of more than 40% and estimated greenhouse-gas emission reductions of 20%. However, production of the composites is more expensive than fibreglass or plastic. In particular, high energy intensity is a major constraint. The composites are also considered difficult to recycle and reuse. Objectives The 'CRESIM' project will demonstrate an innovative pilot process for the production of CFRP composites from recycled carbon fibre. The innovative solution will combine a series of technologies that have been already tested in a pre-industrial prototype plant, and will bridge the gap to full market uptake. The project aims to show how lightweight materials can be used in a wide range of applications, including civil engineering, sports equipment, biomedicine and high-end audio components and musical instruments, whilst achieving considerable environmental benefits for society. Expected results: The design and construction of a pre-industrial prototype process line that is able to produce CFRP composites from recycled carbon fibre, retaining 80-90% of the recycled material's mechanical and structural characteristics; To facilitate the recycling of up to 90% of carbon fibre from manufacturing plant waste; To ensure energy efficiency in the process, with a reduction of up to 80% of energy consumption per kilogramme of product; To define 20 typologies of product that can be produced by the process; To obtain a reduction in production times and costs, thus demonstrating applicability in high-volume series products (such as automotive parts); To showcase the results in order to convince at least six manufacturers to perform re-impregnation tests on at least 180 samples; To define at least four formulations with different chemistry, and adaptations of the manufacturing process that could foster market replication in the EU and worldwide; and To conclude at least one agreement with a recycled carbon fibre supplier for the provision of recycled carbon fibre and the set up of a recycling chain.