Sustainability and economic assessment of an innovative automated filament winding process

Sustainability and economic assessment of an innovative automated filament winding process

BIANCHI Iacopo, DE PRISCO Nello, MANCIA Tommaso, MARTONE Alfonso, PALMIERI Barbara, SIMONCINI Michela, VERDINI Tommaso

download PDF

Abstract. The present paper aims at studying the environmental and economic impacts of an innovative Filament Winding (FW) process used to realize a tubular shape structural component in Carbon Fiber Reinforced Polymer (CFRP). To this purpose, the Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) methodologies were applied using a “from cradle to grave” approach. Specifically, a towbar used for aircraft pushback was considered as case study. All phases of the life cycle of the analyzed component were included (from the raw materials extraction to the disposal phase). The comparison between the CFRP towbar investigated and a traditional one in aluminum alloy was performed. The LCC analysis was conducted by considering all costs associated with the automated filament winding process, from the initial investment costs. For all the considered impact categories, the CFRP towbar showed the lowest environmental impacts, mainly due to both the reduced weight and service life fuel consumption. The cost and carbon footprint of the innovative component were associated with raw materials use.

Filament Winding, CFRP, LCA, LCC

Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: BIANCHI Iacopo, DE PRISCO Nello, MANCIA Tommaso, MARTONE Alfonso, PALMIERI Barbara, SIMONCINI Michela, VERDINI Tommaso, Sustainability and economic assessment of an innovative automated filament winding process, Materials Research Proceedings, Vol. 41, pp 2861-2870, 2024


The article was published as article 313 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] M.A. Mateen, D.V. Ravi Shankar, M. Manzoor Hussain, Design and development of low cost two axis filament winding machine, Journal of Advanced Manufacturing Technology. 12 (2018) 117–126.
[2] M. Azeem, H.H. Ya, M. Kumar, P. Stabla, M. Smolnicki, L. Gemi, R. Khan, T. Ahmed, Q. Ma, M.R. Sadique, A.A. Mokhtar, M. Mustapha, Application of Filament Winding Technology in Composite Pressure Vessels and Challenges: A Review, J Energy Storage. 49 (2022) 103468.
[3] Ö.S. Sahin, A. Akdemir, A. Avci, L. Gemi, Fatigue crack growth behavior of filament wound composite pipes in corrosive environment, Journal of Reinforced Plastics and Composites. 28 (2009) 2957–2970.
[4] A. Vita, V. Castorani, M. Germani, M. Marconi, Comparative life cycle assessment and cost analysis of autoclave and pressure bag molding for producing CFRP components, International Journal of Advanced Manufacturing Technology. 105 (2019) 1967–1982.
[5] S. wen Chen, H. Liu, F. hai Li, Analysis of Boeing 737 aircraft towing accidents, Eng Fail Anal. 80 (2017) 234–240.
[6] S. Das, Life cycle assessment of carbon fiber-reinforced polymer composites, International Journal of Life Cycle Assessment. 16 (2011) 268–282.
[7] G.D. Shrigandhi, B.S. Kothavale, Biodegradable composites for filament winding process, in: Mater Today Proc, 2021: pp. 2762–2768.
[8] W. Polini, L. Sorrentino, Design of winding with two rovings for cost efficiency and quality in robotized filament winding, in: Proceedings of the ASME Design Engineering Technical Conference, 2003: pp. 177–186.
[9] E. Wilson, C. Karr, S. Messimer, Genetic algorithm optimization of a filament winding process modeled in WITNESS, Materials and Manufacturing Processes. 18 (2003) 509–521.
[10] T. Schneider, L. Wietschel, D. Schüppel, J. Riesner, K. Konrad, A. Thorenz, A. Tuma, D. Koch, Multicriteria optimization as enabler for Sustainable Ceramic Matrix Composites, Int J Appl Ceram Technol. 19 (2022) 3247–3254.
[11] R. Rasheed, I. Anwar, F. Tahir, A. Rizwan, H. Javed, F. Sharif, Techno-economic and environmental sustainability analysis of filament-winding versus pultrusion based glass-fiber composite technologies, Environmental Science and Pollution Research. 30 (2023) 36276–36293.
[12] P. Mindermann, M.G. Pérez, J. Knippers, G.T. Gresser, Investigation of the Fabrication Suitability, Structural Performance, and Sustainability of Natural Fibers in Coreless Filament Winding, Volume 15, Issue 9. 15 (3260).
[13] B. Iacopo, F. Archimede, G. Francesco, G. Luciano, M. Chiara, T. Giulio, Process and structural simulation for the development of a pressure vessel through filament winding technology, Materials Research Proceedings. 28 (2023) 347–356.
[14] C. Laval, CADWIND 2006 – 20 years of filament winding experience, Reinforced Plastics. 50 (2006) 34–37.
[15] A. Forcellese, M. Marconi, M. Simoncini, A. Vita, Life cycle impact assessment of different manufacturing technologies for automotive CFRP components, J Clean Prod. 271 (2020).
[16] L. Postacchini, M. Simoncini, A. Forcellese, M. Bevilacqua, F.E. Ciarapica, G. Andreassi, A.C. Russo, Environmental assessment of an automated impregnation process of carbon fiber tows, in: Procedia CIRP, 2020: pp. 445–450.
[17] A. Benitez, C. Wulf, A. de Palmenaer, M. Lengersdorf, T. Röding, T. Grube, M. Robinius, D. Stolten, W. Kuckshinrichs, Ecological assessment of fuel cell electric vehicles with special focus on type IV carbon fiber hydrogen tank, J Clean Prod. 278 (2021).
[18] W. Kloepffer, Life cycle sustainability assessment of products (with Comments by Helias A. Udo de Haes, p. 95), International Journal of Life Cycle Assessment. 13 (2008) 89–95.
[19] R. Tong, Cost Analysis on L-shape Composite Componenet Manufacturing, in: 2012.