Environmental Impact of an Innovative Aeronautic Carbon Composite Manufactured via Heated Vacuum-Assisted Resin Transfer Molding

Abstract

The Vacuum-Assisted Resin Transfer Molding (VARTM) process has gained popularity as a reliable and cost-effective alternative to autoclave molding for high-performance composite production, which is especially interesting for aeronautics, where weight reduction is crucial. However, to date, the environmental impact of components produced through VARTM remains relatively unknown. To address this gap, this study applied the Life Cycle Assessment (LCA) methodology to estimate the environmental impact of a thermoset composite laminate produced through heated VARTM. Aiming to support the decision, the VARTM composite part’s production was compared to conventional autoclave manufacturing, and the influence of alternative end-of-life (EoL) scenarios and energy mixes was considered, through LCA. The study found that energy consumption represented the majority of the environmental impacts of the heated VARTM component (33%), followed by carbon fibers, resins, consumables, and wastes. In terms of the comparative analysis, the autoclave manufacturing process showed better environmental results. Regarding EoL management, supercritical hydrolysis (with heat recovery) recycling emerges as the most beneficial method, reducing the impacts of the VARTM-manufactured component by 25%. This study emphasizes the importance of sustainable practices, such as reducing energy consumption, using low-carbon energy mixes, and adopting recycling methods to improve VARTM composite’s environmental performance.