Green Composite: AI-Based Fabrication, Characterization, Evaluation, and Application

Green composites, composed of natural fibers, biopolymer matrices, and recycled waste constituents, represent a sustainable alternative to conventional synthetic composites. However, their widespread adoption is hindered by challenges such as variability in biomass feedstocks, inconsistent material properties, and inefficiencies in traditional fabrication processes. Recent advancements in artificial intelligence (AI), particularly in machine learning and deep learning, offer transformative solutions to these issues. AI technologies optimize material formulations, enhance manufacturing precision, and enable real-time defect detection, thereby revolutionizing traditional processing paradigms. This chapter provides a comprehensive evaluation of AI-integrated fabrication approaches compared to conventional methods, emphasizing their impact on material performance and industrial scalability. AI-driven methodologies facilitate predictive modeling and data-driven process optimization, improving raw material utilization efficiency and minimizing production waste. Furthermore, intelligent manufacturing systems equipped with adaptive AI control mechanisms ensure consistent product quality and significantly reduce prototyping time. Collectively, these advancements enhance reproducibility, operational efficiency, and the sustainability profile of green composite manufacturing. Despite these benefits, significant limitations remain, including the scarcity of high-resolution datasets, the need for domain-specific AI model customization, and the computational intensity of real-time applications. Nevertheless, integrating AI into sustainable materials science holds substantial potential for advancing industrial adoption. Developing intelligent and sustainable manufacturing frameworks is essential for scaling green composite technologies across industries, such as automotive, aerospace, construction, and consumer goods. The strategic application of AI in the green composites sector not only improves environmental outcomes and economic feasibility but also drives technological innovation. This convergence supports the global transition toward a circular, low-carbon economy, aligning with broader sustainability objectives.