The development of new materials that are inherently safe and sustainable has become a critical objective in the context of the green transition. This challenge is especially significant for plastics, which often contain complex mixtures of chemicals that may be released during various stages of their life cycle and that can pose risks to human health and the environment. Within this context, the Safe and Sustainable by Design (SSbD) framework was followed to support the design of an innovative epoxy–vitrimer composite that integrates non-releasable fire-retardant functionalities, aiming to produce safer, sustainable, and recyclable materials suitable for railway applications. A simple methodology was developed to identify release hotspots potentially affecting workers, consumers, and environmental species and organisms. Based on this, experimental simulations were conducted to evaluate the release of materials such as flame retardants, non-intentionally added substances, and microplastics at hotspots and to compare release profiles between a benchmark material and an SSbD alternative. The results demonstrate that the newly developed recyclable and less hazardous composites can also reduce material release under weathering and abrasion conditions.

The development of new chemicals and materials that are inherently safe and sustainable throughout their entire life cycle has become a critical objective in the context of the green transition. This challenge is especially significant for plastics, which often contain complex mixtures of chemicals that may be released during various stages of their life cycle, from manufacturing to use and end-of-life management. Such releases can pose risks to human health and the environment. Within this context, the Safe and Sustainable by Design (SSbD) framework was followed to support the design of an innovative epoxy-vitrimer composite that integrates non-releasable fire-retardant functionalities, aiming to produce a safer, recyclable materials suitable for railway applications. This study presents the identification and quantification of potential releases as part of Steps 2 and 3 of the SSbD framework. A dedicated methodology was established to evaluate the potential release of materials such as flame retardants, non-intentionally added substances, and microplastics throughout the product’s life cycle. A systematic template was developed to identify release hotspots potentially affecting workers, consumers, and environmental species and organisms. Based on these findings, experimental simulations were conducted to compare release profiles between a benchmark and the SSbD alternative.