Search Results (554)

This study investigates the mechanical behaviour of continuous carbon-fibre-reinforced additively manufactured composite structures aimed at applications in aeronautical structures, through a combination of experimental testing and numerical simulation. Tensile, compressive, and shear tests established stiffness and failure characteristics, while finite element analyses were used for a preliminary calibration-based reproduction of the measured coupon response, with an emphasis on the initial elastic part of the impact event. The integration of measured data with structural modelling provides a clearer understanding of load transfer and damage initiation in continuous-fibre AM, supporting more accurate simulation-based design of additively manufactured composite components. Experimental results show pronounced anisotropy, and a stable, rate-dependent impact response. The preliminary numerical model based on CT-derived homogenized properties accurately reproduces the initial part of the measured quasi-static and dynamic responses. Full article

The escalating financial burden of deteriorating civil infrastructure worldwide necessitates a shift from conventional repair methods towards more durable and economically efficient long-term solutions. This paper presents a comprehensive techno-economic review of using carbon fibre-reinforced polymer (CFRP) fabrics for structural strengthening. Moving beyond a simple first-cost comparison, this review utilizes a life-cycle cost analysis (LCCA) framework to evaluate the total cost of ownership. The analysis deconstructs the complete cost profile, demonstrating that while CFRP systems have a high initial material cost, this is frequently offset by substantial savings in labour, equipment, and, critically, the indirect costs associated with reduced construction time and operational disruption. Furthermore, the inherent corrosion immunity of CFRP virtually eliminates future maintenance and repair expenditures, leading to a lower total life-cycle cost compared to traditional steel or concrete-based methods in a wide range of applications. Specifically, the conducted LCCA case study demonstrates that the CFRP alternative can reduce total life-cycle costs by nearly 25% relative to conventional steel sheet bonding, overwhelmingly driven by minimized operational downtime and related indirect costs. The value proposition is shown to be context-dependent, driven by minimizing user delay costs in bridges, mitigating catastrophic risk in seismic retrofitting, preserving cultural value in heritage structures, and maximizing revenue uptime in industrial facilities. The review also examines market dynamics, including the roles of standardization and government policy in driving adoption, and explores future trends such as inorganic matrix composites (TRM/FRCM), integrated structural health monitoring (SHM), and the push towards a circular economy. The findings conclude that a holistic, life-cycle-based economic assessment establishes CFRP strengthening as a cornerstone technology for the sustainable and resilient management of modern civil infrastructure. Full article

This work presents a methodology for the generation of continuous fibre trajectories based on principal stress directions in continuous fibre-reinforced additive manufacturing (CFAM). The material system considered consists of continuous carbon fibre (CCF-1.5K) embedded in a CFC-PA thermoplastic matrix. CFAM enables the deposition of fibres along tailored paths, allowing improved alignment with the load direction, compared to traditional composite manufacturing. In this way, the strong anisotropy of composite materials, typically considered a limitation, is exploited as a design opportunity by aligning fibres with the structural load paths. The proposed approach combines finite element analysis with a path generation procedure, including the computation of principal stress directions, the extraction of streamlines of the principal stress field, and a dedicated post-processing stage aimed at obtaining continuous and manufacturable fibre layouts. The effectiveness of the method is assessed through a finite element-based comparison with conventional fibre configurations, showing an increase in global stiffness of approximately 20% with respect to the best-performing unidirectional layout. In addition, the feasibility of the generated trajectories is demonstrated through printing tests performed on a continuous fibre additive manufacturing system. The results confirm that the proposed methodology enables the generation of physically realizable fibre paths while improving structural performance. Full article

This study presents a novel methodology integrating high-resolution X-ray computed tomography, digital volume correlation and statistical visualisation mapping, to perform microscale observations and correlate delamination fracture mechanisms in heterogeneous materials. To demonstrate the utility of this integrated approach, it is applied to study the damage behaviour of aerospace carbon/epoxy composite laminates with an open hole, subjected to quasi-static tension and fatigue at a load ratio of 1:10. The study also explores the applicability of a Paris law type relationship to determine effective macroscopic fatigue delamination resistance in the load-bearing plies. The X-ray imaging for both load cases revealed extensive formation of delaminated fracture surfaces surrounding both glass fibre interlacing weaves and entrained voids within them, acting as preferential sites for localised strain hot spots. It is demonstrated that local energy dissipation is governed by the recurring weave pattern and topological order, which can help explain the typical damage state in quasi-static behaviour, establishing a direct link between microstructural features and macrostructural material response. Full article

Intralayer hybridisation provides a powerful strategy for tailoring the stiffness–strength–ductility balance of fibre-reinforced composites through architecture control. This study investigates the flexural behaviour of carbon/glass intralayer hybrid composites with varying carbon-to-glass (C:G) ratios and degrees of dispersion using a finite element modelling framework supported by experimental validation against published flexural test data. Four hybrid ratios (C:G = 2:1, 1:1, 1:2, and 1:4) and multiple dispersion levels were examined under three-point bending to quantify the effects of intralayer architecture on flexural strength, modulus, and strain to failure. The results show that carbon-rich hybrids retain high flexural stiffness and strength while achieving substantial improvements in failure strain and damage tolerance compared with pure carbon laminates. In these systems, flexural strength is strongly influenced by dispersion, with moderate-to-high dispersion improving strain compatibility, delaying tensile-side carbon fibre fracture, and enhancing strength. In contrast, glass-dominated hybrids exhibit flexural behaviour that is largely insensitive to dispersion, with strength and modulus following near rule-of-mixtures trends and failure governed by progressive glass fibre and matrix damage. Across all hybrid ratios, flexural modulus is controlled primarily by fibre volume fraction, whereas flexural strength and failure strain depend sensitively on intralayer architecture when carbon fibres remain the dominant load-bearing phase. These findings clarify the respective roles of hybrid ratio and dispersion in governing flexural performance and extend recent studies by demonstrating a systematic transition from dispersion-dominated to ratio-dominated behaviour as glass content increases. The results provide mechanistic insight and practical design guidance for optimising intralayer hybrid composites for lightweight, damage-tolerant structural applications. Full article

The buckling and post-buckling responses of carbon fibre-reinforced polymer (CFRP) structures are strongly affected by geometric imperfections, boundary conditions, and material nonlinearities, making their reliable numerical prediction challenging. This work presents an integrated experimental–numerical investigation of a stiffened CFRP panel subjected to compressive loading, with the aim of improving model validation in instability regimes. The experimental campaign combines full-field measurements obtained through digital image correlation with local strain data from strain gauges, adopting a back-to-back configuration to capture the strain reversal associated with global buckling. The experimental results are compared with nonlinear finite element simulations incorporating intralaminar damage based on Hashin’s failure criteria. A good agreement between the numerical and experimental results is observed in the pre-buckling and early post-buckling regimes. However, increasing discrepancies arise at higher load levels, mainly due to manufacturing imperfections and uncertainties in boundary conditions, which influence the onset and evolution of localized deformation. Statistical indicators are employed to quantitatively assess the correlation between the experimental and numerical responses. The analysis focuses on the key response parameters, including the load–displacement behaviour, out-of-plane displacements, strain evolution, and damage initiation, enabling a comprehensive comparison of experimental and numerical results. The results demonstrate the effectiveness of combining full-field and point-wise measurements for validating numerical models of composite structures. Furthermore, the study highlights the limitations of idealized modelling assumptions and provides insights into the sensitivity of CFRP structures to imperfections in post-buckling and failure regimes. Full article

The focus of this work was to investigate the mechanical properties of additively manufactured (AM) discontinuous carbon fibre-reinforced polymer (DCFRP) composites. Towards the specimen’s fabrication, the Fused Filament Fabrication (FFF) additive manufacturing technique was employed. A number of input printing parameters were varied, such as the infill pattern, infill density, layer height, shell configuration, and raster orientation, in a systematic way. The role of these paraments on the mechanical properties, such as tensile, flexural, and impact strength were investigated. The data was analysed in-depth and the “main effect method” was employed for their comparative ranking. The results of this study showed that tensile and bending strengths were strongly correlated with material content and structural reinforcement. The specimens attained up to 76.7 MPa of tensile strength, while the flexural strength was up to 159.4 MPa, with a deflection of up to 8 mm and 16 mm, respectively. Solid infills, higher densities, finer layer heights, and added shells significantly improved the strength and stiffness. Grid-patterned and low-density specimens caused poor load-bearing capacities, while hexagonal and gyroid infills offered a more balanced performance. Full article

This research work is aimed at developing and manufacturing thermoplastic-composite parts for a Type V hydrogen storage tank based on a patented design. A 57% fibre volume fraction of a carbon fibre and polyamide 11 (PA11) thermoplastic matrix was used in an automated tape layup (ATL) process to manufacture a laser-assisted in situ-consolidated composite part for a hydrogen storage vessel. A series of mechanical and thermal tests were performed to optimize the process parameters for composite manufacturing. Based on the optimized process parameters, a scaled-up demonstrator composite part was manufactured and demoulded using pressurized air. Full article

Earth-based additive manufacturing (AM) combines design flexibility and automation of 3D printing (3DP) with low embodied energy, local availability, and circular economy compatibility of earthen materials. However, the sustainability performance of earth-based AM remains contested, particularly when chemical stabilisers and fibres are introduced to address mechanical and durability limitations. This review examines earth-based AM, focusing on fibre reinforcement, mechanical performance, and environmental impacts. Following PRISMA guidelines, peer-reviewed open-access articles (2015–2025) were identified and analysed using the Web of Science database. The review synthesises findings on material compositions, processing strategies, mechanical behaviour, and life cycle assessments of 3D-printed earthen materials, with particular attention to natural fibres. Results show that fibre reinforcement primarily contributes to crack control, post-peak behaviour, dimensional stability, and printability rather than universal strength enhancement. Compressive strengths range from 1–3 MPa for non-stabilised printed earth to 6–25 MPa for stabilised systems, confirming stabilisation as critical for structural scalability. Environmental assessments reveal that despite low-carbon feedstocks, 3D-printed earth can exhibit higher carbon emissions than conventional earthen techniques due to binder use and energy-intensive printing unless material savings and circular strategies are optimised. Key gaps include heterogeneous testing protocols, limited structural-scale validation, and insufficient techno-economic integration. Full article

Composite materials have traditionally been employed in the aerospace sector due to their ability to withstand highly demanding service conditions. In recent years, their application has expanded significantly into other engineering domains, including wind energy, shipbuilding, and the automotive industry. The design of composite structures often involves geometric discontinuities, such as cut-outs for access or fastener holes for mechanical joining, which typically become critical regions under load. Consequently, the stress concentrations induced by notches represent a major concern, as they can lead to substantial reductions in strength compared with unnotched laminates. A comprehensive understanding of the behaviour of notched specimens is therefore essential for the design of complex composite assemblies, where components are commonly joined using bolts and rivets. The objective of this study is to examine the tensile response and notch sensitivity of carbon fibre-reinforced polymer (CFRP) laminates with different stacking sequences, through a comparative analysis of unnotched and open-hole specimens. A central circular hole was introduced to reproduce the geometric discontinuities frequently encountered in structural applications, enabling a detailed assessment of stress concentration effects. The experimental results indicate that unidirectional laminates exhibit the highest sensitivity to notches, whereas quasi-isotropic configurations among the multidirectional laminates display the most pronounced reduction in strength, approaching 50%. Moreover, the Point Stress Criterion (PSC) and the Average Stress Criterion (ASC) were employed to determine the characteristic lengths of the specimens, revealing significant differences among the values obtained for each lay-up configuration. Overall, the findings highlight the strong influence of stacking sequence on the mechanical response of notched CFRP laminates and underscore the need to further refine existing failure criteria to accommodate novel laminate architectures, including Bouligand-type helicoidal bioinspired stacking sequences. Full article

The near-surface mounted (NSM) technique with carbon fibre-reinforced polymer (CFRP) composites has been proven to be one of the most effective alternatives for the flexural strengthening of existing reinforced concrete (RC) members. However, several issues remain unresolved, including the effects of elevated temperatures on the performance of these strengthened RC elements. This study experimentally investigates the mechanical performance of RC slabs strengthened with NSM-CFRP systems under elevated temperatures, using both (i) steady-state and (ii) transient heating under applied loads. The steady-state tests were conducted at 20, 40, 50, 70, and 80 °C, while the transient tests were performed at 20 and 80 °C. Deflections, strains, temperatures and loads were registered during the heating phase and during the flexural tests up to failure. These measurements were used to analyse the system response in terms of load–deflection curves, evolution of concrete and CFRP strains, and bond stresses between the epoxy adhesive and CFRP. At 80 °C, the NSM-CFRP-strengthened RC slabs exhibited an average reduction of 12.1% (steady-state) and 2.3% (transient) in ultimate strength. Moreover, the concrete crushing failure mode governed up to 70 °C, despite passing the epoxy’s glass transition temperature (54 °C), while cohesive failure of the adhesive governed the failure at 80 °C. Full article

The concept of self-healing polymers has been prevalent over the last few decades. However, their performance and behaviour in structural applications in the form of layered composites have not been studied extensively. In this study, an attempt has been made to evaluate the recovery of the mechanical properties of Carbon Fibre-Reinforced Polymer composites (CFRPs) with an intrinsically healable polymeric resin system. Destructive tests, including static tensile, compression, and flexural tests, are carried out to evaluate their ability to recover mechanical compliance after healing. Nondestructive tests based on the Acousto-Ultrasonic (AU) approach are carried out to establish and distinguish the state of these composites. The results show that the tested self-healing CFRPs can recover their mechanical properties, particularly their flexural and compressive properties, after unstable matrix damage. On the other hand, the AU approach, supported by Machine Learning (ML) models, demonstrates that the damaged states and the heal states of these composites can be distinguished from the virgin state. Full article

With Aligned Formable Fibre Technology (AFFT^™), fibers are reformatted into highly oriented epoxy prepreg tapes, enabling the structural reuse of recycled composite waste. The present study investigates whether discontinuous fiber laminates produced with AFFT^™ can be characterized and optimized with the same finite-element workflows long established for continuous fiber composites and whether the resulting structures meet demanding stiffness targets. Initially, various manufacturing methods were adopted, including vacuum bagging, compression molding at 7 bar to simulate autoclave conditions, and compression molding at 90 bar, comprising the three most reasonable manufacturing processes for AFFT^™ laminates. Experimentally measured orthotropic properties were introduced into a finite-element model representing an idealized bicycle top tube, which was chosen as a case study. A genetic algorithm screened candidate stacking sequences, minimizing the combined bending-and-torsion deflection. The best lay-ups reduced deformation by more than 30% compared to a quasi-isotropic baseline, showing that well-oriented short fibers can significantly contribute to the stiffness of composites. Tubes produced with the optimized lay-up were tested in three-point bending tests, and the measured stiffness matched simulations within 5%. These results confirm a key point for sustainable engineering: despite the absence of continuous fibers, conventional simulation strategies accurately predict the performance of AFFT^™ laminates and can be used as the basis for effective genetic optimization. This validation is significant: it enables the design of stiff, high-performance structures from recycled materials using established, cost-effective methods. By proving that optimization strategies developed for traditional continuous fiber composites apply to AFFT^™, this study offers a trusted and accessible pathway to scale circular economy solutions in next-generation composite products. Full article

This research delves into the impact of varying printing angles in the range (0°, 15°, 30°, 45°) on the thermal and mechanical characteristics of carbon fibre–PLA/PHA composites fabricated via fused filament fabrication (FFF). The microstructural arrangement within the 3D-printed PLA/PHA is unveiled through the application of SEM, X-ray microtomography and optical imaging. Tensile loading conditions are employed to extract meaningful mechanical parameters such as Young’s modulus, tensile strength, elongation at break, and mechanical energy, all of which are associated with the printing angle settings. The results indicate that the filaments exhibit a porosity of approximately 3%, while the porosity of the printed structure ranges from 27% to 38%, depending on the printing angle. Tensile modulus in the range 840 to 890 MPa is found not to be highly sensitive to the printing angle. However, tensile strength reaches 37 MPa for a printing angle of 30°. The variations across conditions are limited to approximately 6% in tensile stiffness and 16% in tensile strength. Finite element simulations based on 3D imaging indicate that an effective modulus of the solid phase between 1.6 and 1.8 GPa provides the closest agreement between experimental measurements and numerical predictions. This study presents novel findings concerning the deformation mechanisms associated with different length scales, from filament composite to filament arrangement, in the carbon fibre–PLA/PHA composite. This study highlights that while printing angle has a moderate influence on mechanical response, the overall structural integrity and interlayer cohesion of carbon fibre–PLA/PHA composites remain robust across a wide range of processing parameters, demonstrating their potential for reliable structural applications in additive manufacturing. Full article

In the automotive industry, the push for lightweighting, sustainability, and performance underpins the need for continuous improvement of materials and processes; thus, this research explores the introduction of different approaches for processing optimization. The Finite Element Method (FEM) excels at enhancing structural efficiency and reducing material use in composite tooling like stamping dies, while Life Cycle Assessment (LCA) quantifies environmental impacts over the product life cycle. Coupling these approaches is promising but challenging due to difficult integration into well-established industrial practices. In this framework, the study presents the combination of FEM-LCA analyses on a tool for a composite car bonnet, considering an industrial case. The reduction in weight (−85%) obtained through FEM topology optimization, along with novel materials (thermoplastic polymers) and processes (3D printing, internal recycling), results in an environmental impact reduction over the tooling process (−43% in climate change). The two analyses enable a holistic tool design that balances mechanical performance with reduced carbon footprint, aligning with the European regulatory framework and emission targets. The results demonstrate the feasibility of a coupled FEM-LCA approach to optimize composite tooling in the automotive context, with a positive prospect of full-scale integration into the industrial value chain. Full article