Process chain based data capture for a flexible and reliable life cycle inventory of a glass fiber-reinforced thermoplastic lightweight structure

In recent years, fiber-reinforced polymers (FRP) found their way into automotive serial production. This was motivated by vehicle weight reduction resulting in decreased fuel consumption in the use phase. Due to the complexity of FRP manufacturing processes, only few data for life cycle inventory (LCI) are available in databases. Furthermore, a widespread range of LCA results can be attained in dependence of the actual process parameters and part design. In order to keep up with the composite technology development, a process chain based data capturing is required taking into account deviations from the target state. This contribution therefore suggests the combination of LCI with process chain analysis. In the FOREL project FuPro, an innovative process chain for manufacturing of functionalized hollow profiles made of glass fiber-reinforced thermoplastics was developed. It comprises several steps, which cannot be evaluated using state-of-the-art databases. Hence, technologically and ecologically relevant data were captured. For this purpose, a gate-to-gate perspective was used. The process steps of plasma treatment and IR heating are selected. The presented course of action provides a resilient and flexible basis for LCA, which prospectively allows a goal-oriented multi-criteria analysis and derivation of best practice process management.