The use of lightweight components in automobiles started a new chapter in the automotive sector due to the renewable energy and sustainability increasing the overall efficiency of vehicles. As vehicle weight is directly linked to energy consumption, reducing mass through advanced materials can significantly decrease energy usage and emissions over the vehicle’s lifetime. This present study aims to conduct a preliminary life cycle assessment (LCA) of a prototype battery pack manufactured using pultruded composite materials with a volume fraction of 50% glass fibers and a volume fraction of 50% nylon 6 (PA6) matrix by quantifying the CO₂ emissions and cumulative energy demand (CED) associated with each stage of the battery pack’s life cycle, encompassing production, usage, and end-of-life recycling. The results of the EuCia Eco Impact Calculator and from the literature reveal that the raw materials extraction and use phases are the most energy-intensive and contribute mainly to the environmental footprint of the battery pack. For a single battery pack for EV, the CED is 13,629.9 MJ, and the CO₂ eq emissions during production are 1323.9 kg. These results highlight the need for innovations in material sourcing and design strategies to mitigate these impacts. Moreover, the variations in recycling methods were assessed using a sensitivity analysis to understand how they affect the overall environmental impact of the system. Specifically, shifting from mechanical recycling to pyrolysis results in an increase of 4% to 19% of the total CO₂ emissions (kg CO₂). Future goals include building a laboratory-scale model based on the prototype described in this paper to compare the environmental impacts considering equal mechanical properties with alternatives currently used in the automotive industry, such as aluminum and steel alloys.

In recent years, environmental sustainability has become a key issue in the shipbuilding industry, driving research towards a reduction in the environmental impact throughout the entire life cycle of vessels. In this context, composite materials are a solid alternative to achieve mechanical performance optimization and energy consumption reduction. This study compares two hull configurations, one in a glass fiber-reinforced thermoset composite and one in a thermoplastic composite sandwich structure, through life cycle assessment. The aim is to assess the influence of material choice and structural configuration on overall environmental impacts by analyzing energy and material inputs and emissions throughout the entire life cycle, from “cradle to grave” excluding the end-of-life treatment. The results evidence a 36% average reduction in the impact categories analyzed. Moreover, economic benefits emerged, with a 35% reduction in the cost of energy required during the analyzed life cycle phases and 9% reduction in the material supply. This work aims to contribute to the definition of more sustainable design strategies to produce hulls and naval components, promoting a transition towards a more efficient and environmentally friendly nautical sector.

Electroplasticity in sheet metal forming is a relatively recent method that involves applying an electric current to metal sheets during or before the forming process. Existing research on Electro-Assisted (EA) forming primarily focused on material characterization; few studies have investigated the effect of electropulsing on loads, power, and energy consumption during sheet metal forming, and no studies have explored the reshaping of previously formed titanium sheets after the Electro-pulsed treatment (EPT). This research aims to bridge some of these gaps of knowledge by applying two different electropulsing treatments, varying in current density, to square Ti6Al4V specimens prior to shaping and reshaping. performed using dies and counter dies having different geometries. Load, power, and energy consumption data were measured to assess the benefits of EPT compared to an untreated specimen serving as a reference. The findings suggest that EPT can significantly reduce the energy consumption and forces required for both shaping and reshaping of titanium components, extending their useful life and reducing the need for remelting. The study highlights the potential of EPT as a sustainable solution for reducing the environmental impact of titanium sheet disposal and recycling, improving material efficiency, and optimizing industrial forming processes.

This work focuses on the pultrusion of pre-consolidated tapes made of virgin polypropylene reinforced with glass fiber. A specially designed laboratory-scale pultrusion line was used, consisting of a heating/forming mold, a cooling mold, and the pulling system. A life cycle assessment was conducted to evaluate the environmental impact of producing a pultruded composite material with a constant cross-section of 100 mm² and a length of one meter. The cradle-to-gate approach was chosen to model the pultrusion process, which involves the three stages mentioned above. The analysis was performed using the CML 2016 method in the LCA for Experts (Sphera) software. The data used in this work to model the cradle-to-gate scenario are mainly derived from experimental measurements taken during the pultrusion process using sensors and from the literature. The specific Energy Consumption (SEC) was calculated for both operational conditions (1.41 MJ/m at v120 to 0.905 MJ/m at v180). Despite the defects found, the samples taken from the pultruded profile showed significant interlaminar shear strength (120 mm/min of 83.7 ± 9.6 MPa compared to 63.5 ± 17.3 MPa at 180 mm/min).