Carbon fiber goes green as German researchers ditch oil for algae

German researchers at the Technical University of Munich (TUM), through the GreenCarbon project, have developed an innovative process to produce aircraft-grade carbon fiber from photosynthetic microalgae instead of petroleum. By converting algae oils into glycerol and then into acrylonitrile—the key precursor for carbon fiber—they have created a bio-based alternative to the traditional fossil fuel-derived acrylonitrile. This method, refined in partnership with the Fraunhofer Institute and carbon manufacturer SGL Carbon, yields carbon fibers that match the mechanical strength and resilience of conventional fibers, enabling their use in high-performance applications without major changes to existing manufacturing processes. The project’s success was demonstrated when Airbus used the algae-derived carbon fiber to build components for a research helicopter that flew in 2024, marking a significant step toward sustainable aviation manufacturing. Beyond aerospace, the lightweight, strong materials have potential uses in wind turbines, vehicles, and sports equipment. Importantly, because microalgae absorb CO₂ during growth, this approach offers a