Synergistic AHP-TOPSIS and RSM Framework for Multi-Criteria Optimization of Sustainable Hybrid Composite Laminates

This study presents an integrated, data-driven framework for the optimal selection and design of high-performance hybrid composite laminates. Epoxy-based composites reinforced with jute, glass, and carbon fibers were fabricated in six distinct stacking sequences and systematically evaluated for tensile strength, flexural strength, tensile modulus, flexural modulus, and break strain. To rigorously assess differences among configurations, one-way ANOVA followed by Tukey’s HSD post-hoc test was employed, confirming statistically significant differences in mechanical performance ( p < 0.001) across all properties. The CG4C (cross-ply laminate) configuration, featuring carbon fibers on the outer layers and glass fibers internally, demonstrated the highest flexural strength (228.44 MPa) and tensile modulus (7.72 GPa), while JCGs (balanced laminate) achieved superior tensile strength (301.00 MPa) and break strain (16.93%). Multi-criteria decision-making using AHP and TOPSIS was then applied to rank the configurations, with CG4C emerging as the top choice for high-stiffness applications and JCGs for ductility-critical uses. The rankings were validated and refined using RSM, which modelled the nonlinear effects of laminate type and stacking sequence on mechanical responses. High predictive accuracy ( R ² > 0.90 for modulus and break strain) and desirability-based multi-objective optimization further confirmed the superiority of the CG4C laminate. This integrated methodology not only identifies optimal stacking configurations but also quantifies trade-offs between strength, stiffness, and ductility, providing actionable design guidelines for structural, automotive, and aerospace applications. The strong agreement between statistical analysis, AHP-TOPSIS rankings, and RSM-predicted performance validates the robustness of this framework for sustainable hybrid composite development.