Composite materials permit the reduction of weight at no compromise on mechanical resistance, hence they are selected for their performances, and represent the selection of choice in all the applications where lightweight needs to be combined with high stiffness and rigidity. Still, issues are raised on their sustainability, and heavy research efforts are spent for the recycling of composites, through the thermal route (pyrolysis) and the chemical route (solvolysis).

A new approach to reach the sustainability target within the ZeroWasteLIFE project arises from reaching breakthrough performances in terms of wastes avoidance, combined with a modular design for replacement –reuse of parts. The process of High Volume Tailored Fiber Placement (HV-TFP) is consisting of three steps: stitching of multiple filaments on flat pattern from 3D-2D flattening; 2D – 3D reconstruction of the final solid product through moulding; consolidation through autoclave or hot pressing. Thanks to the deposition of reinforcements only where needed, the project is expected to reduce the wastes, improve the materials efficiency, reducing at the same time the costs for the final materials and their rate of reusability, thanks also to modular design.

The project outcome is validated through two different demo products: automotive part, and a part of satellite, testifying the advantages reached also in the aerospace sector, already optimizing the features of products. A reduced net impact of 15% energy and CO2 emissions, and 40% raw materials will be demonstrated, leading to a strong impact on product acceptability. The overall sustainability is assessed through Environmental, societal and industrial-economic LCA. The project long-term expected impacts are 18 GWh energy and 30 k tons CO2 emissions reduction at the European level, creating healthier world for the EU citizens, thanks to direct exploitation at partner sites, and licensing exploitation to unlock at EU level the advantages generated.