Sustainable Lightweight Materials for Aerospace Interiors: A DataDriven Comparison of BioBased and Recycled Composites with Traditional Aluminium Alloys

The aerospace industry is actively seeking sustainable alternatives to traditional materials that can meet performance requirements while reducing environmental impact. This study investigates the potential of bio-based and recycled composites to replace aluminium alloy 2024-T3 in aircraft interior applications, where weight reduction directly translates to fuel savings and lower emissions. Through comprehensive data analysis, we examine flax fibre- epoxy composites and recycled carbon fibre-thermoplastic composites as promising sustainable alternatives. Our methodology involves systematic collection and analysis of mechanical properties, environmental impact data, and cost information from NASA technical reports, material databases, industry publications, and peer-reviewed literature. We employ multi-criteria decision analysis (MCDM) to evaluate trade-offs between performance metrics including specific strength, specific stiffness, and durability against sustainability indicators such as carbon footprint, recyclability, and raw material renewability. The research addresses critical gaps in understanding how these emerging materials compare to aerospace-grade aluminium when considering both technical and environmental criteria simultaneously. Special attention is given to the challenges and opportunities these materials present for secondary structural applications, where certification requirements are less stringent than primary structures. This data-driven approach provides a framework for evaluating sustainable material options without requiring expensive laboratory testing, making it accessible for researchers and engineers in developing countries or institutions with limited experimental facilities. The findings contribute to ongoing efforts to decarbonize aviation while maintaining the safety and performance standards essential to aerospace applications, supporting the industry's commitment to achieving net-zero emissions by 2050.