Additive manufacturing (AM) of composite materials is promising to create customizable products with enhanced properties, utilizing materials like carbon fibers (CFs). To increase their circularity, composite recycling has been proposed to re-introduce the recovered components in AM. A careful evaluation of recycling is necessary, considering the sustainability and functionality (i.e., mechanical properties) of the recovered components. Thus, Life Cycle Assessment (LCA) is applied to estimate the environmental impacts of AM via Fused Filament Fabrication (FFF), using virgin or recycled CFs via solvolysis at a laboratory scale. This study aims to provide a detailed Life Cycle Inventory (LCI) of FFF and evaluate the sustainability of using recycled CFs in AM. For both virgin CF manufacturing and CF recycling, electricity consumption was the main contributor to environmental impacts. CF recovery via solvolysis resulted in lower impacts across most impact categories compared to AM with virgin CFs. Different scenarios were examined to account for the mechanical properties of recycled CFs. AM with 75% recycled CFs, compared to 100% virgin CFs undergoing landfilling, resulted in over 22% reduction in climate change potential, even after a 50% loss of recycled CF functionality. Overall, this study offers insights into the LCI of FFF and shows that CF recycling from composites is worth pursuing.

The building sector accounts for 40% of the total energy consumed in Europe at annual basis, together with the relevant Greenhouse Gas (GHG) emissions. In order to mitigate these impacts, the concept and establishment of the Nearly Zero Energy Buildings (NZEBs) is under continuous and intensive research. In fact, as the energy used for buildings’ operation becomes more efficient, impacts resulting from the buildings’ embodied energy become of more importance. Therefore, the selection of building materials and components is of high significance, as these affect the energy performance and potential environmental impacts of the building envelopes. The objective of this study is to perform a preliminary Life Cycle Assessment (LCA) on advanced multifunctional building components, aiming to achieve lower embodied emissions in NZEBs. The advanced components analyzed are composite panels for facade elements of building envelopes, providing thermal efficiency. The design of sustainable building envelope systems is expected to upgrade the overall environmental performance of buildings, including the NZEBs. The findings of this study constitute unambiguous evidence on the need for further research on this topic, as substantial lack of data concerning embodied impacts is presented in literature, adding to the growing discussion on NZEBs at a whole life cycle perspective across Europe. This research has shown that the electricity required from the manufacturing phase of the examined building components is the main contributor to climate change impact and the other environmental categories assessed. Sensitivity analysis that has been performed indicated that the climate change impact is highly depended on the electricity grid energy mix across Europe. Taking into account the current green energy transition by the increase of the renewable energy sources in electricity production, as well as the future upgrade of the manufacturing processes, it is expected that this climate change impact will be mitigated. Finally, the comparison between the CLC thermal insulator and other foam concretes in literature showed that the materials of the building components examined do not present any diversions in terms of environmental impact.

This study performs a Life Cycle Assessment on the production of a commercial PCM building application developed by RUBITHERM to quantify its environmental impacts and identify environmental hotspots across manufacturing, unlocking climate change mitigation potential. This research adds to the consideration of embodied energy demands and emissions when developing building efficiency solutions, especially for innovative material applications where knowledge is limited. The building application under examination is a compact storage module, consisting of an aluminium case filled with salt hydrate PCM, with a targeted performance of 94 Wh heat storage capacity. The LCA of the manufacturing stage resulted in a climate change impact of 5.81 kg CO₂ eq. The research showed that the aluminium of the case to be filled in with PCM is the main contributor to almost all impact categories addressed, including climate change, while the sensitivity analysis revealed that the total climate change of the final product is highly dependent on the recycled aluminium content, which could be decreased by 46% by increasing the new scrap and post-consumer scrap aluminium streams. Finally, the study provides detailed Life Cycle Inventory data, based on real data shared by RUBITHERM, and methodology transparency to facilitate built-up research in the field.

This study investigates the materials and fabrication selection criteria for 3D-printed aluminosilicate components aimed for passive cooling and CO₂ adsorption in indoor conditions, considering their manufacturing environmental impact. The dual-function components were fabricated using Liquid Deposition Modelling (LDM), an Additive Manufacturing (AM) technique utilising customised slurry-based feedstock materials. To assess the environmental implications of the production process, the study employs the Life Cycle Assessment (LCA) methodology, a standardised framework used to quantify potential environmental impacts across the product’s life cycle. The study outlines a systematic approach to materials and fabrication processes selection, focusing on the functional properties required, the importance of locally sourced materials, and the constraints imposed by the fabrication techniques. The fabrication methodology was analysed for material/energy efficiency and waste generation. Post-processing stages were evaluated to identify opportunities for energy savings, particularly by exploring Low-Temperature Firing (LTF). The selected criteria proved efficient in enhancing shaping control and minimising shrinkage variability, with a recorded weight loss of 3.04% via LTF. The LCA results indicated that the 23% reduction in climate change impact was primarily driven by the lower electricity demand of the LTF Protocol, demonstrating that energy-efficient post-processing is a critical lever for sustainable ceramic fabrication.