Abstract
Fiber-metal laminates (FMLs) are high-performance hybrid materials that integrate metal layers with fiber-reinforced polymer (FRP) composites to achieve superior strength-to-weight ratios. This study presents a comparative cradle-to-gate Life Cycle Assessment (LCA) of six distinct FML configurations, focusing on the environmental influence of fiber selection and metal surface treatment. The FMLs utilized AA2024-T3 aluminium alloy as facing layers, integrated with various high-performance fabrics: Basalt, Aramid, Zylon, and Innegra. A significant contribution of this research is the development of original inventory datasets for these specialized fiber fabrics, which were previously limited in existing databases. Using OpenLCA software with the ecoinvent 3.12 database and the ReCiPe 2016 Midpoint (H) method, the study integrates detailed surface treatment processes—specifically chemical anodizing and mechanical abrasion—directly into the LCA framework. The analysis identifies critical environmental hotspots, demonstrating that the choice of interfacial treatment and fiber type significantly dictates the sustainability profile of the laminate. The findings underscore the necessity of eco-design strategies in FML development, advocating for the substitution of high-impact components, the adoption of low-impact surface treatments, and the integration of energy-efficient manufacturing to advance circular economy pathways for hybrid composite systems.
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Funding
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie SkłodowskaCurie Grant Agreement ID : 101202017.
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Pai, A., Rodriguez-Millan, M., Shenoy Baloor, S. et al. Eco-design and life cycle characterization of fiber-metal laminates for sustainable manufacturing and resource efficiency. Sci Rep (2026). https://doi.org/10.1038/s41598-026-50250-6
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DOI: https://doi.org/10.1038/s41598-026-50250-6
