Unveiling Sustainable Potential: A Life Cycle Assessment of Plant–Fiber Composite Microcellular Foam Molded Automotive Components

Abstract

The development and utilization of new plant–fiber composite materials and microcellular foam molding processes for the manufacturing of automotive components are effective approaches when achieving the lightweight, low-carbon, and sustainable development of automobiles. However, current research in this field has mainly focused on component performance development and functional exploration, with a limited assessment of environmental performance, which fails to meet the requirements of the current green and sustainable development agenda. In this study, based on a life cycle assessment, the resource, and environmental impacts of plant–fiber composite material automotive components and microcellular foam molding processes were investigated. Furthermore, a combined approach to digital twinning and life cycle evaluation was proposed to conduct resource and environmental assessments and analysis. The research results indicate that under current technological conditions, resource and environmental issues associated with plant–fiber composite material automotive components are significantly higher than those of traditional material components, mainly due to differences in their early-stage processes and the consumption of electrical energy and chemical raw materials. It is noteworthy that electricity consumption is the largest influencing factor that causes environmental issues throughout the life cycle, especially accounting for more than 42% of indicators such as ozone depletion, fossil resource consumption, and carbon dioxide emissions. Additionally, the microcellular foam molding process can effectively reduce the environmental impact of products by approximately 15% and exhibits better overall environmental performance compared to chemical foaming. In future development, optimizing the forming process of plant–fiber composite materials, increasing the proportion of clean energy use, and promoting the adoption of microcellular foam injection molding processes could be crucial for the green and sustainable development of automotive components.