The disposal of wind turbine blade (WTB) waste presents a growing environmental concern due to its substantial volume and composite material complexity. This study introduces a novel strategy to mitigate this issue by repurposing WTB-derived glass fibers (GF) into high-performance polyacrylonitrile (PAN)-based composite fibers. A scalable dry-jet wet spinning combined with a forced assembly process was employed to fabricate 256-layered PAN-GF composite fibers, with micrometer-scale control over alternating layers of pure PAN and PAN-GF. This architecture promoted uniform GF dispersion and improved alignment via interfacial shear stress. Incorporating 1–4 wt.% GF led to significant mechanical enhancements, with Young’s modulus increasing by 54.7% (from 15.10 GPa to 23.37 GPa) and tensile strength improving by 27.2% (from 521.71 MPa to 663.66 MPa) compared to neat PAN fibers. Mechanical, thermal, and structural characterizations—including tensile testing, Differential Scanning Calorimetry (DSC), Dynamic Mechanical Analysis (DMA), and X-ray Diffraction (XRD) confirmed the beneficial impact of GF incorporation on the composite’s performance. Subsequent heat treatment yielded carbonized fibers (CF) with exceptional thermal stability, demonstrating their potential for advanced structural and energy applications in extreme environments.
