Environmental and Economic Analysis of Composite Manufacturing Process Using Innovative Photonic-Based Integrated Sensors

Abstract The increasing adoption of composite materials in sectors such as aerospace, automotive, and energy highlights the need for more sustainable and efficient manufacturing processes. This study presents an integrated environmental and economic evaluation of a novel photonic-based sensor system designed to improve quality control during composite manufacturing. The sensor, embedded directly into composite tooling, enables real-time, high-precision monitoring of critical process parameters. A comprehensive life cycle costing (LCC) model, developed using a hybrid bottom-up and activity-based approach, is employed to assess the economic performance of the sensor across both prototype and scaled production scenarios. Simultaneously, a life cycle assessment (LCA) framework is used to evaluate the environmental impact. The analysis reveals that labour is the primary cost driver, and production efficiency is highly sensitive to learning curve effects and regional labour rates. The findings indicate that the sensor system offers significant potential for reducing costs and environmental impact, supporting its viability for industrial deployment.