System and method for converting recycled carbon fiber into densified fibers

A method of densification of recycled pre-preg fibers, the method comprising:

• removing resin from pre-preg material via sonication in a recycler to extract recycled pre- preg fibers from the pre-preg material;
• receiving the recycled pre-preg fibers having various lengths and a first bulk density;
• cutting the recycled pre-preg fibers to produce cut fibers having a desired length;
• wetting the cut fibers with water;
• and
• mixing the wetted, cut fibers to generate bound fibers having a second bulk density that is increased relative to the first bulk density of the cut fibers,
• wherein cutting the recycled pre-preg fibers comprises cutting the recycled pre-preg fibers in a hammermill,
• wherein the method further comprises passing the cut fibers through a screen configured to pass cut fibers having the desired length after cutting the recycled pre-preg fibers in the hammermill to achieve the desired length of about 0.02 inches to about 0.375 inches, and
• wherein the cut fibers are wetted with water prior to mixing to bind only parallel fibers aligned linearly with respective ends proximate each other to form the bound fibers.