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STRUCTURAL AND MATERIAL OPTIMIZATION OF A COMPOSITE AIRBOX: LCA ANALYSIS FOR A FORMULA STUDENT VEHICLE
Abstract
This study focuses on the structural and material optimization of a composite airbox for a Formula Student vehicle from the perspective of Life Cycle Assessment (LCA). Three evolutionary airbox generations are analyzed, each differing in geometry, number of parts, and material configuration, while maintaining the same primary manufacturing technology, in which the core structural material is a carbon fiber prepreg cured in an autoclave. The design optimization includes shell geometry simplification, integration of previously separate components, and the reduction or complete replacement of metallic parts with polymer components produced via 3D printing. The LCA was conducted in Sphera GaBi Professional 2025.1 using the Ecoinvent 3.9.1 database, within cradle-to-gate system boundaries and applying the TRACI 2.1 method with a focus on the Global Warming Potential (GWP) indicator. The results show that between the first and third airbox generations, mass is reduced by approximately 30%, while the material-related carbon footprint decreases by about 34%. Carbon composite remains the dominant material hotspot across all generations. Generations with a higher share of aluminum exhibit increased GWP not only due to their higher mass but also because aluminum machining waste is not recycled within the current manufacturing scenario. The study discusses limitations related to the use of a single functional unit, the exclusive focus on the GWP category, and the absence of recycling scenarios for metallic and composite waste, and it outlines directions for future research. The findings are relevant not only to motorsport and automotive applications but also to other industries that utilize CFRP components with high stiffness-to-weight requirements. The results support the goals of SDG 9 (Industry, Innovation and Infrastructure) and SDG 12 (Responsible Consumption and Production) by integrating LCA early in the design process and may contribute to the development of industrial guidelines or standards for environmentally responsible composite component design.
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References4
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