Recycling fabric waste into composite materials for the applications of lightweight vehicle body & circular economy

Fabric scrap waste in the textile and garment industry consists of leftover or unused fabric pieces from the cutting and sewing processes. Managing fabric waste is essential for environmental sustainability and cost-effectiveness in the textile sector. Common types of fabric scrap include trim waste, cutting room scrap, and defective or off-cut pieces. Efficient scrap management reduces environmental impact, lowers costs, and enhances operational efficiency. As sustainability demands grow, industries are adopting innovative strategies to minimize waste and optimize production. This study investigates the mechanical (tensile, flexural, and impact) and thermal properties of fabric scrap-reinforced composite materials. Thermogravimetric analysis was performed to assess their thermal stability. Experimental results revealed that chopped fabric scrap composites outperformed sandwich and laminated forms in mechanical performance. The optimal composition was identified as a 40% reinforcement and 60% matrix weight ratio. According to the test results, the maximum tensile and flexural strength were obtained at chopped orientation, with values of 110 and 112 MPa, respectively. Regarding the hardness test, almost all three orientations showed similar results at the described ratio. The findings suggest that fabric scrap-reinforced polyester composites have significant potential for automotive applications, particularly in vehicle hoods, bumpers, and roofing. Moreover, this study emphasizes the role of recycled textile composites in promoting a circular economy, bridging the automotive and textile industries. By integrating waste materials into high-performance composites, this approach supports sustainability efforts through waste reduction and resource optimization, making it a viable solution for eco-friendly manufacturing.