Sustainable Electronics
Lighter, stronger, greener: the UK’s composite revolution
By Sam Hudson, managing director, BAMD Composites T
he UK’s electronics manufacturing sector is undergoing a profound transformation. Confronted by the dual challenges of global competition and the urgent need to decarbonise, industries are turning to advanced materials and innovative processes to build a more sustainable, resilient future. At the heart of this transformation lies one material technology that continues to redefine the boundaries of performance and sustainability: composites.
Recognised by the UK Government as a key growth sector within its industrial strategy, composites are driving innovation across aerospace, automotive, defence, renewable energy, and medtech. British-made composite materials are now powering global industries where strength, weight reduction, and sustainability are paramount. The result is a sector that not only advances engineering excellence but also generates skilled jobs, export potential, and economic growth.
The growing importance of composites in the electronics manufacturing industry Composites are increasingly central to the electronics manufacturing industry, particularly where weight reduction, thermal management, and structural performance are critical. They are used in housings, circuit boards, heat sinks, and enclosures for high- reliability applications. Their combination of high strength, low weight, dimensional stability, and electromagnetic shielding makes them ideal for components where performance and reliability cannot be compromised. In aerospace electronics, composites reduce the mass of avionics housings, improving fuel efficiency and device reliability. In automotive electronics, they support EV battery enclosures, electronic control units, and lightweight chassis components. In renewable energy, composites are used for durable, lightweight housings for power electronics and control systems. Across these applications, designers are increasingly seeking materials that balance performance with environmental responsibility, a demand eco-composites are uniquely positioned to meet.
20 December/January 2026
Eco-composites and sustainability in electronics manufacturing Sustainability in the electronics manufacturing industry is a challenge that can no longer be ignored. Component designers are under pressure to reduce environmental impact while maintaining safety, reliability, and performance. Eco- composites, which integrate bio-based resins or natural fibres, now offer a solution for high-performance electronics components. BAMD’s work with Toyota Gazoo Racing illustrates this potential. Supplying a complete suite of eco-composite body panels for the new GR Supra Supercar, BAMD delivered components with a significantly lower carbon footprint compared to traditional epoxy and pre-preg carbon fibre processes. These materials allow for energy-efficient curing, lower embodied carbon, and performance parity with conventional systems. Lifecycle assessments show that eco- composites can reduce CO2
emissions by up
to 40 per cent compared with conventional composite materials, depending on part design and production method. Importantly, this sustainability gain does not come at the expense of performance: the panels demonstrate the structural rigidity, thermal stability, and dimensional precision necessary for high-speed applications where electronics and mechanical performance intersect. For this project, we designed, tooled, and manufactured a full suite of eco-composite
Components in Electronics
body panels entirely at our Oxfordshire facility. The programme, completed within just twelve weeks from concept to race-ready components, demonstrates the strength of the UK’s end-to-end manufacturing capabilities.
Sustainability in this context is not about compromise; it is about engineering progress. Motorsport provides an ideal proving ground because the tolerance for error is minimal and the demand for performance is absolute. The success of the Toyota GR Supra project demonstrates that sustainable composites can meet the same high standards of dimensional accuracy, repeatability, and strength as traditional systems, while offering meaningful environmental benefits.
Technical precision and sustainable process innovation
Sustainability must be embedded across every stage of electronics component production. A turnkey approach, from design refinement and tooling to composite lay-up, curing, and inspection, ensures consistency, efficiency, and waste minimisation. Using advanced CAD/ CAM software and digital twin modelling, it is possible to optimise each component before tooling begins, ensuring that materials are used as efficiently as possible. Key process improvements include: Employing closed-loop vacuum systems and reusable mould tooling to reduce consumable waste.
Using Computer Numerical Control (CNC) machining for precision trimming and material nesting, increasing yield and reducing offcuts.
Where offcuts are produced, developing reuse loops to reprocess composite waste into secondary applications such as tooling boards or non-structural housings. This focus on efficiency and reuse should form part of a long-term strategy to support a circular economy within advanced and electronics manufacturing. The combination of eco-composite materials, material efficiency, and process innovation allows businesses to minimise environmental impact without compromising technical standards. At BAMD, applying this integrated approach enables the delivery of complete, right-first-time solutions that help leading manufacturers such as Toyota adopt sustainable practices at scale - demonstrating that environmentally responsible design can also achieve competitive performance and cost efficiency.
Government strategy and the role of the National Composites Centre The UK Government has identified composites as a strategic technology area, recognising their role in national security, industrial competitiveness, and net-zero delivery. The National Composites Centre (NCC), part of the High Value Manufacturing Catapult, continues to play a vital role in bridging the gap
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