Sustainable meso-conical cup fabrication using recycled e-waste-derived copper: a hybrid RSM–Spherical Fuzzy AHP–fuzzy GRA optimization approach
Abstract
This study investigates meso-conical cup fabrication using as-received copper (AR) and a recycled copper-based composite feedstock (EW) containing 30 wt.% recovered e-waste-derived copper and 70 wt.% as-received copper. To achieve this, we developed a hybrid Response Surface Methodology (RSM)–Spherical Fuzzy AHP–Fuzzy Grey Relational Analysis (GRA) framework in which feed rate, depth, step size, and material type were treated as control factors. At the same time, surface roughness, dimensional accuracy, production cost and energy consumption were selected as response variables. The findings revealed a pronounced quality–cost–energy trade-off. The A14 condition (AR, 20 mm/min feed, 0.15 mm depth, and 0.10 mm step size) delivered the best quality performance, achieving 1.0 µm surface roughness and 97.0% dimensional accuracy. In contrast, the A10 condition (EW, 30 mm/min feed, 0.15 mm depth, and 0.10 mm step size) had lower production cost (₹6.383/part) and energy consumption (2.289 Wh/part) than A14 (₹9.291/part and 3.294 Wh/part). Relative to A10, A14 improved surface roughness by 28.57% and dimensional accuracy by 1.57%, but increased cost by 45.56% and energy use by 43.91%. The results show that partially incorporating recovered e-waste-derived copper is technically feasible and can reduce production cost and operational energy demand under selected conditions. However, the AR condition remains preferable when surface finishes and dimensional accuracy are the primary requirements.
Related
- Introducing a sustainable method for stabilizing clay using industrial sludge ash and recycled polyethylene terephthalate fibers
- Acoustic Optimization and Standardized Fabrication of a Biomimetic Liver Phantom for Quantitative Multimodal Imaging
- Sustainable valorization of Piennolo tomato leaves (Solanum lycopersicum L.) as a source of rutin: extraction optimization, antiglycation activity, and ex vivo skin distribution
- Date pomace valorization for sustainable mushroom mycelial biomass and bioactive compound production using Taguchi optimization
- Marginal Bone Loss and Peri-Implant Clinical Outcomes of Internal Hexagonal and Internal Conical Implant Abutment Connections: A Narrative Review.
BibTeX
@article{sivam2026sustainable,
title = {{Sustainable meso-conical cup fabrication using recycled e-waste-derived copper: a hybrid RSM–Spherical Fuzzy AHP–fuzzy GRA optimization approach}},
author = {S. P. Sundar Singh Sivam and Prince Jeya Lal Lazar and Stalin Kesavan and A. Johnson Santhosh},
journal = {Scientific Reports},
year = {2026},
month = oct,
doi = {10.1038/s41598-026-75545-6},
url = {https://www.nature.com/articles/s41598-026-75545-6},
note = {CC BY-NC-ND 4.0},
}
RIS
TY - JOUR
TI - Sustainable meso-conical cup fabrication using recycled e-waste-derived copper: a hybrid RSM–Spherical Fuzzy AHP–fuzzy GRA optimization approach
AU - S. P. Sundar Singh Sivam
AU - Prince Jeya Lal Lazar
AU - Stalin Kesavan
AU - A. Johnson Santhosh
PY - 2026
DA - 2026/10/19
JO - Scientific Reports
DO - 10.1038/s41598-026-75545-6
UR - https://www.nature.com/articles/s41598-026-75545-6
AB - This study investigates meso-conical cup fabrication using as-received copper (AR) and a recycled copper-based composite feedstock (EW) containing 30 wt.% recovered e-waste-derived copper and 70 wt.% as-received copper. To achieve this, we developed a hybrid Response Surface Methodology (RSM)–Spherical Fuzzy AHP–Fuzzy Grey Relational Analysis (GRA) framework in which feed rate, depth, step size, and material type were treated as control factors. At the same time, surface roughness, dimensional accuracy, production cost and energy consumption were selected as response variables. The findings revealed a pronounced quality–cost–energy trade-off. The A14 condition (AR, 20 mm/min feed, 0.15 mm depth, and 0.10 mm step size) delivered the best quality performance, achieving 1.0 µm surface roughness and 97.0% dimensional accuracy. In contrast, the A10 condition (EW, 30 mm/min feed, 0.15 mm depth, and 0.10 mm step size) had lower production cost (₹6.383/part) and energy consumption (2.289 Wh/part) than A14 (₹9.291/part and 3.294 Wh/part). Relative to A10, A14 improved surface roughness by 28.57% and dimensional accuracy by 1.57%, but increased cost by 45.56% and energy use by 43.91%. The results show that partially incorporating recovered e-waste-derived copper is technically feasible and can reduce production cost and operational energy demand under selected conditions. However, the AR condition remains preferable when surface finishes and dimensional accuracy are the primary requirements.
SN - 2045-2322
ER -