Environmental performance of self-reinforced composites in automotive applications — Case study on a heavy truck component

• A LCA of a novel self-reinforced composite material (SrPET) is presented, using an automotive body panel as case study.
• The environmental performance of SrPET was compared to a thermoset composite material (SMC) and a thermoplastic blend (PC/PET).
• The design concept based on SrPET is lighter and performs better in terms of life cycle CED and GWP with 25% lower impact.
• With high recyclability potential SrPET is a competitive material for replacing non-recyclable composites.

A screening environmental life cycle analysis (LCA) of the novel self-reinforced poly(ethylene therephthalate) (SrPET) is presented in this paper. A truck exterior panel is used as case study where a concept design made by SrPET is assessed and compared to a glass fibre reinforced composite and a thermoplastic blend that are currently used for the selected component. The results showed that the SrPET panel has 25% lower environmental impact compared to the current design, with no significant life cycle trade-offs. SrPET offers possibilities for weight reduction while maintaining good mechanical properties. As the impact during use phase is expected to decrease in the future the relative importance of manufacturing and end-of-life (EOL) will increase. Thus SrPET can be considered a competitive material for replacing existing energy intense non-recyclable composites.

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