Life cycle assessment research and industrial reality in the composites sector: A systematic review

Fiber-reinforced polymer composites are high-performance materials increasingly used in multiple fields of application, offering advantages while also facing challenges regarding environmental sustainability. Despite an increasing number of Life Cycle Assessments (LCA), existing reviews on composites remain limited in scope and critical stance. This paper presents a systematic review of 130 original articles on LCA of composites examining technical aspects of composite products, and LCA methodological choices. They were compared to industrial data considering material types, manufacturing, field of application and waste treatment. The review stresses discrepancies between assessed issues in LCA and their importance in industrial context. Particularly, bio-based composites and recycling receive high attention in LCA research compared to their market shares, while some industrially-relevant materials and applications are underrepresented in LCA. It also underlines frequent differences in technological maturity in LCA studies, which influences results especially for emerging materials and processes. Four methodological choices were selected for in-depth analysis: system model and database selection, functional unit description, system boundary definition, and modelling of composite life cycle stages. Intransparency and inconsistency on these choices in multiple studies highlight the discrepancy between LCA theory and its application to composites. Recommendations address the inclusion of composite level of quality, lifetime, and system boundaries reflecting specific applications of composites. They also tackle multifunctionality and biogenic carbon accounting, pleading for methodologically consistent and technically realistic approaches. Despite limitations, the joint approach adopted in this review can help other sectors in enhancing the usefulness of LCA to guide industrial developments towards reduced environmental impacts.
While they offer major advantages, they also face challenges regarding environmental sustainability. Despite the growing number of Life Cycle Assessments (LCA) analyzing the environmental impacts of these materials, existing reviews on composites remain limited in scope and critical perspective. This paper presents a systematic review cross-examining technical aspects of composite products, LCA methodological choices, and industrial context. A total of 130 original articles on LCA of composites were identified and compared with industrial data considering fiber and polymer type, manufacturing process, field of application, and waste treatment pathway.
The review highlights discrepancies between the issues assessed in LCA studies and their relevance in industrial practice. In particular, bio-based composites and recycling receive disproportionate attention in LCA research compared to their current market shares, whereas some industrially relevant materials and applications remain underrepresented. The review also underlines frequent differences in technological maturity among LCA studies, which strongly influence results, especially for emerging materials and processes.
Four methodological choices were selected for in-depth analysis: system model and database selection, functional unit description, system boundary definition, and modelling of composite life cycle stages. Intransparency and inconsistency in these choices across multiple studies highlight the gap between LCA theory and its application to composites. Recommendations address the inclusion of composite quality, lifetime, and application-specific system boundaries, while also discussing multifunctionality and biogenic carbon accounting. Despite limitations, the joint approach adopted in this review may support other sectors in improving the usefulness of LCA for guiding industrial developments toward reduced environmental impacts.