The future generation of lightweight materials? A life cycle assessment of fiber-reinforced composite cross car beams

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

Abstract

Fiber-reinforced composites offer promising lightweight alternatives for automotive applications, yet comprehensive life cycle assessments (LCAs) comparing them with conventional metal components remain limited. This study presents the first cradle-to-grave LCA evaluating a recyclable multi-material glass-fiber-reinforced polymer (GFRP) composite cross car beam (CCB) against an aluminium reference, considering 11 CML midpoint impact categories with explicit composite EoL modelling under different scenarios. The study has been conducted as part of a larger research project aimed at supporting the development of a more sustainable GFRP composite CCB. The composite redesign achieves lower cradle-to-grave impacts across 10 of 11 categories, with reductions of 35–37 % in toxicity-related impact categories and 8–16 % in Global Warming Potential. Ozone Depletion Potential represents the only trade-off (∼12–13 % increase), attributable to proxy-based inventory data. Despite replacing ∼40 % of the aluminium mass, residual aluminium supply for the hybrid composite structure dominates upstream impacts, while end-of-life (EoL) recycling credits prove decisive for resource depletion categories. These results indicate that environmental performance in hybrid multi-material composite architectures is governed by metal substitution, scrap minimization, and EoL recycling quality - conditions increasingly decisive as powertrains electrify and electricity grids decarbonize.

Details

Original languageEnglish
Article number113768
Number of pages16
JournalComposites Part B: Engineering
Volume322
Early online date6 May 2026
Publication statusE-pub ahead of print - 6 May 2026
Peer-reviewedYes

External IDs

ORCID /0000-0003-1370-064X/work/214454775
Scopus 105038226949

Keywords

Sustainable Development Goals

Keywords

  • Life Cycle Assessment (LCA), Transport sector, automotive industry, automotive lightweight components, carbon footprint, composites, environmental assessment, fiber-reinforced polymers (FRP)