Early-stage sustainability assessment of a biobased resin replacement for aerospace interiors: A holistic tool to surface circularity and regulatory risk for TRL reviews

Abstract: Aircraft OEMs face growing expectations to deliver sustainable products while navigating limited precedent for assigning sustainability value to early-stage technology development. We present a case study in which a novel biobased resin—designed as a drop-in substitute for phenolic resin in aerospace interior applications—was developed and evaluated using an Excel-based holistic sustainability assessment tool for which a patent is pending. Objectives were to (1) evaluate compatibility of the new bio-based resin chemistry leveraging renewable feedstocks to reduce toxicity and regulatory risk to aerospace-relevant performance requirements, and (2) assess the project’s sustainability value across circularity and multi-criteria ESG metrics to produce an artifact for a Technology Readiness Level (TRL) review. Methods combined materials research and qualification planning with an early-stage screening assessment that flags sustainability risks and benefits across environmental, social, and governance domains. The assessment tool highlights tradeoffs and prompts targeted follow-up analyses—such as life cycle assessment (LCA) or Material Circularity Indicator (MCI) quantification as applicable. Results include an innovative sustainability artifact recommended for incorporation into the established TRL process, demonstration of the tool’s ability to detect sustainability risk early in development, and evidence that quantifying circularity (MCI) materially supported the project’s value proposition. The screening output helped guide design and R&D prioritization, guide supply chain integration, facilitate stakeholder buy-in, and lead to continued funding and advancement of the green chemistry substitution. Integrating a structured sustainability assessment at early TRL checkpoints enables detection and mitigation of environmental sustainability and regulatory risks, strengthens business cases for green chemistry substitutions, and supports responsible production and procurement decisions in the aerospace industry. Adoption of this artifact-driven approach can accelerate scale-up of low-toxicity, circular materials across sectors.