Transforming Machining Waste into Value-Added Materials: A Sustainable Approach for Industrial Innovation and Resource Efficiency

Industrial manufacturing is a major driver of economic development; however, it also generates significant material waste and environmental impact. Wire Electrical Discharge Machining (WEDM), in particular, produces substantial quantities of brass wire waste that are typically discarded after a single use. This study investigates the direct reuse of WEDM brass wire waste as a reinforcement material in composite manufacturing, eliminating the need for energy-intensive recycling processes. Composite samples were fabricated and evaluated through mechanical testing in accordance with ASTM standards. The incorporation of WEDM brass wire waste significantly enhances the mechanical performance of the composite system. At an optimal loading of approximately 20 wt.% (particulate form), the developed composite achieved tensile strength of up to 332 MPa, compared to 19.7 MPa for neat epoxy. This represents a substantial improvement in load-bearing capability, primarily due to enhanced stress transfer and crack resistance mechanisms introduced by the metallic reinforcement. More importantly, the optimized composite demonstrates tensile performance comparable to, and slightly exceeding, conventional fibreglass-reinforced epoxy (GFRE), highlighting its potential as a viable alternative reinforcement material.Overall, this work presents a potentially scalable approach, subject to further industrial validation and process optimization. The findings contribute to SDG 12 (Responsible Consumption and Production), SDG 9 (Industry, Innovation and Infrastructure), and SDG 13 (Climate Action).