Speakers
Description
This work presents a Life Cycle Assessment (LCA) approach for the environmental evaluation of next-generation launch vehicle components based on fibre-reinforced thermoplastic polymer (FRTP) composites. The tool is being implemented and tested within DISAPPEAR, an R&D project funded by ESA and involving Lofith, MT Aerospace, IAA-CSIC, and Arribes, which aims to develop lightweight FRTP composite solutions to replace metallic materials —such as aluminium and steel alloys— in space applications.
To support early-stage engineering decisions, a simplified, decision-oriented LCA tool has been developed. This streamlined framework, aligned with ESA LCA Handbook provisions, focuses on key impact drivers and enables rapid comparison between alternative materials and design configurations. It is conceived as a practical tool to integrate environmental considerations into the design process from the earliest phases, where iterative evaluation and fast feedback are critical.
From a “cradle-to-gate” perspective, FRTP composites offer clear manufacturing advantages. Their high strength-to-weight ratio enables lower material input, while advanced processes such as automated tape placement enhance material efficiency compared to subtractive machining of metallic components. In contrast to metals, which often involve high buy-to-flight ratios, these composite manufacturing techniques allow near-net-shape production, minimizing scrap and associated environmental burdens. Additionally, thermoplastic matrices offer shorter processing cycles and potential for recycling.
Beyond manufacturing, the LCA is extended to address more complex environmental impacts associated with operational use and reentry. Lightweight FRTP components reduce propellant demand during launch, leading to lower upstream impacts from fuel and oxidizer production and transport, as well as decreased direct emissions during combustion. Reentry effects, a relatively underexplored aspect of space systems within LCA, are also considered. Aluminium-based components generate aluminium oxides during ablation, which may contribute to catalytic ozone depletion in the upper atmosphere. In contrast, the decomposition pathways and atmospheric effects of FRTP materials remain largely uncertain. This work includes an initial comparative assessment of these atmospheric effects, contributing to a more comprehensive evaluation of launcher sustainability.
Overall, this work demonstrates how simplified LCA tools can guide eco-design in early engineering stages, while targeted, detailed evaluations of operational and reentry emissions ensure that complex environmental impacts are also considered, supporting the development of greener space technologies.