Compared to the mechanical properties of composites from recycled carbon fibres (rCF) based on moulding compounds and nonwovens, hybrid yarns from rCF and thermoplastic fibre with adjusted yarn properties offer an excellent potential for high fibre orientation, fibre length, compactness, high fibre volume content resulting in a high level of performance in composites. However, the spinning of hybrid yarns from rCF and thermoplastic fibres for carbon fibre rein-forced composites (CFRP) is based on modified roving frame spinning technology with high yarn twists, which are indispensable to ensure sufficient yarn strength and a stable spinning process. However, high yarn twist results in undefined damage to the rCF, increased short fibre content during spinning and poor fibre alignment in the composite. These lead to drafting error, uneven fibre structures and irreproducible manufacturing processes as well as low mechanical properties of CFRP. Therefore, one of the main objectives of this work is to develop zero twist hybrid yarns from recycled carbon fibres for high performance thermoplastic composites. For this purpose, a new concept of false twisting spinning process for the production of twist-free (~0 T/m) hybrid yarns from rCF and thermoplastic fibres based on thermal activation of thermoplastic fibres is developed and patented. This spinning process consists of a modified drafting unit with adjustable gauges and fibre guidance elements for fibres up to 120 mm, a thermo-module, a false twister, a nozzle, take-up rollers and a winder. The new process is expected to help achieve higher tensile strength and modulus in composites compared to rCF hybrid yarns produced on conventional roving frame machines with twists. As a result, the potential of rCF to achieve the high mechanical properties of CFRP can be realised.