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.

In this work, the fracture behaviour of repaired honeycomb/carbon–epoxy sandwich panels under edgewise compression and three-point bending loading was analysed. Assuming the occurrence of damage resulting from a complete perforation leading to an open hole, the followed repair strategy consists of plug filling the core hole and considering two scarf patches with an angle of 10° in order to repair the damaged skins. Experimental tests were performed on undamaged and repaired situations in order to address the alteration in the failure modes and assess the repair efficiency. It was observed that repair recovers a large part of the mechanical properties of the corresponding undamaged case. Additionally, a three-dimensional finite element analysis incorporating a mixed-mode I + II + III cohesive zone model was performed for the repaired cases. Cohesive elements were considered in the several critical regions prone to damage development. The failure modes and the resultant load–displacement curves obtained numerically were compared with the experimental ones. It was concluded that the numerical model is suitable for estimating the fracture behaviour of sandwich panel repairs.

Additive manufacturing (AM) has swiftly emerged as a substitute for conventional methods such as machining and injection moulding. Its appeal is attributed to accelerated prototyping, improved sustainability, and the capacity to fabricate intricate shapes. Nonetheless, the size constraints of additive manufacturing components require the assembly of smaller 3D-printed elements to create larger structures. This study investigates the tensile properties of scarf joints (SJs) created from several polymers, including ABS, PETG, and PLA, adhered with Araldite^® 2015 and Sikaforce^® 7752 adhesives. The characteristics of the adherends were assessed prior to examining the adhesive efficacy in the SJ configuration. Experimental evaluations quantified failure modes, joint strength, assembly stiffness, and energy at failure, comparing findings with predictions from a cohesive zone model (CZM). The objective was to determine the ideal combination of materials and adhesives for enhanced joint performance. Results indicated that joint performance is greatly affected by the adherend material, adhesive selection, and scarf angle. PLA and Araldite^® 2015 typically exhibited optimal strength and stiffness, but Sikaforce^® 7752 demonstrated enhanced energy absorption for extended bonding lengths.

The growing volume of decommissioned wind turbine blades (WTBs) poses substantial challenges for end-of-life (EoL) material management, particularly within the composite repurposing and recycling strategies. This study investigates the repurposing of EoL WTB segments in a full-scale demonstrator for a photovoltaic (PV) floating platform. The design process is supported by a calibrated numerical model replicating the structure’s behaviour under representative operating conditions. The prototype reached Technology Readiness Level 6 (TRL 6) through laboratory-scale wave basin testing, under irregular wave conditions with heights up to 0.22 m. Structural assessment validates deformation limits and identifies critical zones using composite failure criteria. A comparison between two configurations underscores the importance of load continuity and effective load distribution. Additionally, a life cycle assessment (LCA) evaluates environmental impact of the repurposed solution. Results indicate that the demonstrator’s footprint is comparable to those of conventional PV-floating installations reported in the literature. Furthermore, overall sustainability can be significantly enhanced by reducing transport distances associated with repurposed components. The findings support the structural feasibility and environmental value of second-life applications for composite WTB segments, offering a circular and scalable pathway for their integration into aquatic infrastructures.