Recent Advances in Sustainable Composite Materials and Manufacturing

The breadth of polymer-matrix composite materials and manufacturing methods available has led to their adoption across an array of industries, including automotive, aerospace, renewables and high-performance vehicles. However, composites remain characterised by a high carbon footprint and limited recyclability. Consequently, this work aims to identify suitable sustainable composite materials to support a reduction in emissions across the industries employing composite materials. A range of novel materials, including recycled, recyclable, non-wood cellulose and mineral fibres are investigated, quantifying their mechanical properties. This paper provides (i) the experimental characterisation of the ultimate flexural strength of vacuum bagged sustainable composite materials; (ii) supporting evidence that reductions in emissions can be achieved thanks to sustainable composite materials; and (iii) recommendations for where sustainable materials may be employed where they cannot compete with the mechanical properties of carbon fibre, for instance, using recycled carbon fibre as part of the moulds for high-performance parts in advanced manufacturing processes, owing to its coefficient of thermal expansion. These findings provide novel insights into sustainable composite materials and manufacturing to support the decarbonisation of the composite industry, and it is anticipated they may contribute to future regulations and international standards.