Life Cycle Assessment of Zero-Emission Magneto-Rheological Brake with Promising Environmental Performance Compared to Conventional Disc Brake

The European Union is currently focused on reducing non-exhaust emissions (NEE), a growing source of particulate matter (PM) pollution from road transport. This study presents the Life Cycle Assessment (LCA) of an innovative zero-emission magneto-rheological braking system specifically designed to meet new brake emission targets. Prototyped for A-segment passenger cars, the system uses magnetorheological fluids that modify their rheological properties when subjected to an external magnetic field. The environmental impacts of this innovative system are compared with those of a conventional disc brake, considering 16 environmental indicators across all life stages: raw material extraction, manufacturing, use, and end-of-life. In fact, although the system eliminates PM emissions during operation, it is crucial to assess whether it remains advantageous in terms of overall environmental impacts when the full life cycle is considered. As a prototype, this study also aims to inform design improvements that minimize environmental burdens. Results show that the innovative braking system performs better, particularly during the use and maintenance phases. Moreover, several eco-design strategies have been identified to reduce impacts related to materials and production. Overall, the magneto-rheological system demonstrates strong potential to meet future emission standards while improving the sustainability of vehicle braking technology.