In the present investigation an alternative of recycling was evaluated for the residues derived from defective pieces of the ceramic industry, harnessing them as reinforcement in composite materials for the manufacture of parts used in the automotive sector. Sintered clay microparticles to 10% p/p were mixed in an unsaturated polyester resin matrix, through the cast molding technique. Bending tests were performed that showed an elastic-linear behavior, typical of a fragile material. The structure was analyzed through scanning electron microscopy, checking the fragile failure mechanism and a good dispersion of the microparticles. A simulation was carried out with the finite element method, for the design of a motorcycle brake lever, with results that demonstrate a better distribution of stresses and reduction in mass with respect to the original part. Finally, a prototype brake lever was manufactured using computationally validated geometry.

In this research work, samples of the biocomposite were manufactured using the vacuum assisted resin transfer molding (VARTM) technique, whose matrix is a polyester resin and the reinforcement is a biaxial fabric (90°) made with jute fiber. Then, tensile and flexural tests were carried out on standardized specimens under ASTM standards, in order to mechanically characterize the jute-polyester biocomposite. In both destructive tests, the results showed a linear-elastic behavior with brittle fracture and greater strength of the jute-polyester biocomposite, with respect to the thermosetting matrix’s properties. Subsequently, a finite element based static analysis was performed, with the help of the ANSYS software, to determine the mechanical behavior of interior opening handle for a car door. In it, a model sensitivity study was run to determine the influence of the mesh type and identify the convergence of mesh. Later, the static analysis results were obtained: critical zone, maximum operating stress and safety factors. The results obtained computationally validate the use of jute-polyester biocomposite, as a substitute for the manufacture of an interior opening handle for a car door. Finally, a scale model of the piece made with jute-polyester biocomposite was manufactured.

Currently, there is a grown tendency to manufacture environmentally more sustainable composite structures. In this work, a glass fibre reinforced bioepoxy composite was manufactured and submerged in seawater between T = 17[Formula: see text]C and T = 24[Formula: see text]C for a bioactivity period of 6 months. Tensile and flexural tests were performed in order to characterize the new composite before and after seawater immersion. A drop of 20% in Young’s modulus and 9% in tensile strength were observed after immersion. The same trend was analysed in both the flexural modulus and flexural strength, with a fall of 18% and 6%, respectively. It is also remarkable a higher ductility of the specimen after seawater immersion due to a plasticization process by moisture absorption. Those results were confirmed by scanning electron microscopy. Given the mechanical behaviour of the new composite, an L = 6.26 m in length ship hull was designed. Structural analysis was conducted on the suitability and reliability of the composite by using ANSYS software. The simulations revealed the optimal structural performance of the new design even in the extreme sagging situation. To sum up, SuperSap® bioepoxy resin is a suitable matrix to manufacture small glass fibre ship-hulls.

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