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Journal of Polymer & Composites Original Research Special issue

Eco-Efficient Skies: Life Cycle Assessment and Carbon Footprint Minimization of Fiber-Reinforced Polymer Composites in Aerospace Application

  1. Krupal Pawar Department of Mechanical Engineering, Rajiv Gandhi College of Engineering, SPPU, Karjule Harya, Dist. Ahilyanagar
  2. Eknath Bayas Department of Mechanical Engineering, Amrutvahini College of Engineering, SPPU, Sangamner, Dist. Ahilyanagar
  3. Shekhar Rahane Department of Basic Sciences, Nutan Maharashtra Institute of Engineering & Technology, SPPU, Pune
  4. Rajeshkumar Sambhe Department of Mechanical Engineering, Jawaharlal Darda Institute of Engineering & Technology, SGBAU, Yavatmal
  5. Balaprasad Kurpatwar Department of Mechanical Engineering, Adsul’s Technical Campus, SPPU, Chas, Dist. Ahilyanagar

Abstract

The increasing integration of fiber-reinforced polymer (FRP) composites in aerospace structures necessitates a rigorous evaluation of their environmental sustainability throughout their entire life cycle. This study presents a comprehensive life cycle assessment (LCA) and carbon footprint analysis of carbon fiber-reinforced polymer (CFRP) and glass fiber-reinforced polymer (GFRP) composites applied to structural and semi-structural components in commercial aerospace applications. Following ISO 14040/14044 standards and employing the ReCiPe 2016 Midpoint (H) impact assessment methodology, a cradle-to-grave boundary was established encompassing raw material extraction, fiber and matrix production, composite manufacturing, in-service operational phase, and end-of-life treatment. Functional unit was defined as 1 kg of composite structural component delivering equivalent mechanical performance to aluminum alloy AA2024-T3. Results indicate that CFRP manufacturing generates 26.4 kg CO₂ eq./kg compared to 22.8 kg CO₂ eq./kg for GFRP; however, the operational carbon savings attributable to weight reduction approximately 30–50% over aluminum result in a net lifecycle benefit of 189–340 kg CO₂ eq. per kilogram saved over a 25-year aircraft service life. End-of-life recycling via pyrolysis reduced embodied carbon by 12–15%, while combined circular economy strategies achieved up to 59–73% reduction. Bio-based thermoplastic matrices and recycled carbon fiber (rCF) substitution are identified as high-impact decarbonization levers. This study establishes a quantitative sustainability roadmap for aerospace composite material selection, offering decision-support metrics for eco-efficient aircraft design aligned with ICAO Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA) targets.

Keywords

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