Bio-composite materials in door manufacturing : a design and sustainability assessment based on literature and engineering practice

Abstract

Interior doors are typically made of steel, PVC, or hardwood materials that carry high carbon footprints and depend on non-renewable resources. To respond to this sustainability issue, the study investigates bio-composite materials as alternatives for door manufacturing in a design and sustainability context. Methodologically, the work integrates a literature review with practical design engineering, including developing a 3D model in SolidWorks and conducting a simplified Life Cycle Assessment (LCA) to evaluate the design’s environmental impacts. The proposed door design utilizes Wood Plastic Composite (WPC) for the leaf and handle, Cellular WPC (CWPC) for the frame, and a hybrid hinge combining hardwood with AISI 304 stainless steel. This hybrid combination is intended to ensure durability in high-stress points like the hinge while still keeping metal usage minimal. Selected for their performance and eco-friendly attributes, the bio-composites offer adequate mechanical strength and improved moisture resistance while significantly reducing weight owing to CWPC’s lightweight cellular structure. A cradle-to-grave LCA indicates that the bio-composite design yields roughly a 41% lower greenhouse gas footprint than a conventional steel-core door. Additionally, all components are recyclable or recoverable at end-of-life (thermoplastic WPC/CWPC can be reprocessed, wood can be energy-recovered, and steel is fully recyclable). Overall, the findings demonstrate the feasibility of replacing traditional door materials with these bio-composites, achieving substantial reductions in environmental impact without compromising functional performance.