Life Cycle Assessment of composite materials from recycled carbon fibers

In recent decades, the use of carbon fiber-reinforced polymers (CFRPs) in the automotive and aerospace sectors has increased significantly. This trend has led to a corresponding rise in global demand for carbon fibers, as well as a growth in end-of-life composite products and manufacturing waste, with associated environmental challenges. Given the high cost of carbon fibers, the development of innovative recycling solutions represents a clear win–win strategy for improving the life cycle of these materials and enhancing overall environmental and economic sustainability, in line with European standards for the transition toward a circular economy.

This study aims to assess the environmental performance of the production system for consolidated laminates obtained from recycled composite materials from a cradle-to-gate life cycle perspective. The production system is analyzed using the Life Cycle Assessment (LCA) methodology, based on primary data provided by an engineering and manufacturing company within the framework of the Italian MARiS project, funded by the Ministry of Enterprises and Made in Italy.

Environmental impacts are evaluated using SimaPro v.9.6 coupled with the Environmental Footprint 3.1 impact assessment method, with reference to the functional unit of 1 kg of consolidated laminate produced with recycled carbon fibers. The LCA methodology, recognized as a standardized tool for assessing the environmental impacts of products, services, or processes throughout their life cycle, is adopted to identify the main hotspots along the value chain and to explore circular improvement options. The environmental benefits associated with replacing virgin carbon fibers through CFRP recycling are highlighted by comparing the environmental performance of the innovative product (recycling scenario) with that of the conventional product (Business-as-Usual scenario).