Integrated manufacturing of REciclable multi-material COmposites for the TRANSport sector

ABSTRACTGreen polymer composites (GPCs) are increasingly recognised as sustainable alternatives to traditional petroleum?based materials, effectively addressing critical environmental challenges, such as plastic pollution and carbon emissions. These composites include biodegradable polymers, natural fibres, and nanomaterials, which enhance their mechanical properties, durability, and eco?friendly disposal options. However, their widespread industrial adoption faces challenges related to cost, scalability, fibre?matrix compatibility, and regulatory compliance. This study provides a comprehensive review of recent advancements in GPCs, focusing on the preparation methods, reinforcement strategies, and significant performance improvements. Techniques such as melt blending, compression moulding, and additive manufacturing have notably enhanced interfacial bonding and thermal stability. Comparative analyses indicate that GPCs can achieve up to a 30% increase in tensile strength and a 40% reduction in carbon footprint compared with conventional composites. Despite these advantages, ongoing concerns regarding manufacturing costs, processing limitations, and recyclability highlight the necessity for further optimisation. GPCs have diverse applications in various industries, including the automotive sector, biomedicine and scaffolds, packaging and coatings, and constructing reinforced polymer composites for structural applications. Practical implementation must overcome cost barriers and ensure compliance with the global sustainability regulations. Future research should prioritise enhancing the economic viability of GPCs and conducting life cycle assessments (LCA).

» Publication Date: 08/11/2025

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