Search Results (485)

As the importance of sustainability and performance increases, new developments in the manufacturing of fiber-reinforced polymer composites (FRPC) are requested. Ultraviolet (UV) curing offers a faster, more economical, and eco-friendlier alternative to conventionally used thermal curing methods, e.g., autoclave curing, but according to extant research, also presents some shortcomings, such as limitations to thin FRPCs and transparent glass fibers (GFs). This study analyses the UV light transmission in different thermoset FRPCs by irradiating various fiber samples on one side, while a sensor on the opposite side measures the transmitted irradiance. The materials investigated include unidirectional (UD) carbon fibers (CF), UD flax fibers (FF), and six GF fabrics with different ply structures. The fiber samples are tested in a dry, non-impregnated state and a resin-impregnated state using a UV-curable vinyl-ester-based resin. The results show that up to 16 plies of five GF fabrics are fully cured within the 20 s irradiation time and still exhibit a relatively high light transmission, revealing the potential of curing thick FRPCs with UV light. Furthermore, up to three plies of non-transparent FFs are cured, which is promising for the UV curing of natural fibers. Full article

The rheological behavior and low-temperature curing kinetics of poly(ethylene glycol fumarate)–acrylic acid systems initiated by benzoyl peroxide/N,N-dimethylaniline have been investigated for the first time with a focus on the development of thermosetting binders with controllable properties. It has been established that both composition and temperature have a significant effect on rheological behavior and kinetic parameters. Rheological studies revealed non-Newtonian flow behavior and thixotropic properties, while oscillatory tests demonstrated structural transformations during curing. Increasing the temperature was found to accelerate gelation, whereas a higher polyester content retarded the process, which is crucial for controlling the pot life of the reactive mixture. DSC analysis indicated that isothermal curing at 30–40 °C can be satisfactorily described by the Kamal autocatalytic model, whereas at 20 °C, at later stages, and at higher polyester contents, diffusion control becomes significant. The thermal behavior of cured systems was investigated using thermogravimetry. Calculations using the isoconversional Kissinger–Akahira–Sunose and Friedman methods confirmed an increase in the apparent activation energy for thermal decomposition, suggesting a stabilizing effect of poly(ethylene glycol fumarate) in the polymer structure. The studied systems are characterized by controllable kinetics, tunable viscosity, and high thermal stability, making them promising thermosetting binders for applications in composites, construction, paints and coatings, and adhesives. Full article

The transition to electric mobility has intensified efforts to develop battery technologies that are not only high-performing but also environmentally sustainable. A critical element in battery system design is the structural housing, which must provide effective impact protection to ensure passenger safety and prevent catastrophic failures. This study examines the impact response of an innovative sheet molding compound (SMC) composite battery housing, manufactured from an Elium resin modified with Martinal ATH matrix, reinforced with glass fibers, that combines fire resistance and recyclability, unlike conventional thermoset and metallic housings. The material was characterized through standardized mechanical tests, and its impact performance was evaluated via drop-weight experiments on plates and a full-scale housing. The impact tests were conducted at varying energy levels to induce barely visible impact damage (BVID) and visible impact damage (VID). A finite element model was developed in LS-DYNA using the experimentally derived material properties and was validated against the impact tests. Parametric simulations of ground and pole collisions revealed the critical velocity thresholds at which housing deformation begins to affect the first battery cells, while lower-energy impacts were absorbed without compromising the pack. The study provides one of the first combined experimental and numerical assessments of Elium SMC in battery enclosures, emphasizing its potential as a sustainable alternative for next-generation battery systems for transport applications. Full article

Fibre-reinforced composites are facing new challenges in the context particular in sustainability and recyclability. Vitrimers could be useful as new matrices to support the increase in sustainability. Due to their high strength, which is comparable to that of thermosets often used in composites, and their covalent adaptive networks, which make them reshapeable for scaled-up manufacturing and recycling purposes, they are very useful. Orthogonal cutting is used for precise reshaping and functional integration into carbon fibre reinforced plastics. Vitrimers could improve processing results at the cutting edge as well as surface quality thanks to their self-healing properties compared to brittle matrices, as well as enabling the recycling of formed chips and scrap. This study showcases the manufacturing of a carbon fibre-reinforced vitrimer using 4-aminophenyl disulfide as a hardener, with vacuum-assisted resin infusion. The temperature of chip formation and the cutting parameters are then shown for different fibre orientations, cutting widths and speeds. The observed cutting forces are lower (less than 140 N) and more irregular for fibre orientations 45°/135°, increasing with cutting depth, and fluctuating periodically during machining. Despite varying cutting speeds, the forces remain relatively constant in range between 85 N and 175 N for 0°/90° fibre orientation and 50 N and 120 N for 45°/135° fibre orientation, with no significant tool wear observed and lower-damage depth and overhanging fibres observed for 0°/90° fibre orientation. Damage observation of the cutting tool shows promising results, with lower abrasion observed compared to thermoset matrices. Microscopic images of the broached surface also show good quality, which could be improved by self-healing of the matrix at higher temperatures. Temperature measurements of chip formation using a high-speed camera show a high temperature gradient as cutting speeds increase, but the temperature only ever exceeds 180 °C at cutting speeds of 150 m/min, ensuring reprocessability since this is below the degradation temperature. Therefore, orthogonal cutting of vitrimers can impact sustainable composite processing. Full article

Wind power is integral to the transformation of energy systems towards sustainability. However, the increasing number of wind turbines approaching the end of their service life presents significant challenges in terms of waste management and environmental sustainability. Rotor blades, typically composed of thermoset polymer composites reinforced with glass or carbon fibres, are particularly problematic due to their low recyclability and complex material structure. The aim of this article is to provide a system-level review of current end-of-life strategies for wind turbine components, with particular emphasis on blade recycling and decision-oriented comparison, and its integration into circular economy frameworks. The paper explores three main pathways: operational life extension through predictive maintenance and design optimisation; upcycling and second-life applications; and advanced recycling techniques, including mechanical, thermal, and chemical methods, and reports qualitative/quantitative indicators together with an indicative Technology Readiness Level (TRL). Recent innovations, such as solvolysis, microwave-assisted pyrolysis, and supercritical fluid treatment, offer promising recovery rates but face technological and economic as well as environmental compliance limitations. In parallel, the review considers deployment maturity and economics, including an indicative mapping of cost and deployment status to support decision-making. Simultaneously, reuse applications in the construction and infrastructure sectors—such as concrete additives or repurposed structural elements—demonstrate viable low-energy alternatives to full material recovery, although regulatory barriers remain. The study also highlights the importance of systemic approaches, including Extended Producer Responsibility (EPR), Digital Product Passports and EU-aligned policy/finance instruments, and cross-sectoral collaboration. These instruments are essential for enhancing material traceability and fostering industrial symbiosis. In conclusion, there is no universal solution for wind turbine blade recycling. Effective integration of circular principles will require tailored strategies, interdisciplinary research, and bankable policy support. Addressing these challenges is crucial for minimising the environmental footprint of the wind energy sector. Full article

Thermoset fibre-reinforced composites are widely used in high-end industries, but a growing demand for more sustainable and recyclable alternatives conveyed the research efforts towards thermoplastics. To expand their usage, new approaches to their manufacture and mechanical performance must be tackled and tailored to each engineering challenge. The present study designed, manufactured and tested advanced multi-layer laminated composites of thermoplastic polypropylene prepreg reinforced with continuous woven fibreglass with interlayer toughening through thermoplastic polyurethane elastomer (TPU) layers manufactured by fused filament fabrication. The manufacturing process was iteratively optimized, resulting in successful adhesion between layers. Three composite configurations were produced: baseline glass fibre polypropylene (GFPP) prepreg and two multi-layer composites, with solid and honeycomb structured TPU layers. Thermal and mechanical analyses were conducted with both the polyurethane elastomer and the manufactured laminates. Tensile testing was conducted on additively manufactured polyurethane elastomer specimens, while laminated composites were tested in three-point bending. The results demonstrated the potential of the developed laminates. TPU multi-layer laminates exhibit higher thermal stability compared to the baseline GFPP prepreg-based composites. The addition of elastomeric layers decreases the flexural modulus but increases the ability to sustain plastic deformation. Multi-layer laminate composites presenting honeycomb TPU layers exhibit improved geometric and mechanical consistency, lower delamination and fibre breakage, and a high elastic recoverability after testing. Full article

Compared with traditional continuous plant fiber-reinforced thermoplastic composites, their 3D-printed counterparts offer distinct advantages in the rapid fabrication of complex geometries with integrated forming capabilities. However, the impregnation process of continuous plant fiber yarn with thermoplastic resin presents greater technical challenges compared to conventional synthetic fibers (e.g., carbon or glass fibers) typically employed in continuous fiber composites, owing to the yarn’s unique twisted structure. In addition, low molding pressure during 3D printing makes resin impregnation more difficult. To address the impregnation difficulty within plant fiber yarn during 3D printing, we employed two low-viscosity resins, liquid thermoplastic resin (specifically, reactive methyl methacrylate) and thermosetting epoxy resin, to pre-impregnate flax yarns, respectively. A dual-resin prepreg filament is developed for 3D printing of flax fiber-reinforced composites, involving re-coating pre-impregnated flax yarns with polylactic acid. The experimental results indicate that liquid thermoplastic resin-impregnated composites exhibit enhanced mechanical properties, surpassing the epoxy system by 39% in tensile strength and 29% in modulus, attributed to improved impregnation and better interfacial compatibility. This preparation method demonstrates the feasibility of utilizing liquid thermoplastic resin in 3D-printed continuous plant fiber composites, offering a novel approach for producing highly impregnated continuous fiber filaments. Full article

This study investigates the potential of hemp fiber reinforcement in wood–sodium silicate composites for additive manufacturing. It focuses on the impact of hemp fiber length and content on the rheological, flexural, compression properties, and extrudability of the composite. Composites contained varying amounts of sodium silicate (45, 50, 55 wt%) and hemp fibers of varying lengths (1, 3, 5 mm) and amounts (2.5, 5, 10 wt%) along with wood fibers sifted through a 40-mesh sieve. The study shows that higher sodium silicate content significantly increases viscosity while reducing the motor power needed to extrude the composite. Hemp fiber amount positively affects flexural and compression strength, increasing by 31.2% and 35.6%, respectively, with 5 wt% hemp fiber. This improvement in mechanical properties significantly increases the thermoset-based composite’s potential for various applications. This study also demonstrates for the first time, the feasibility of using the hemp fiber-reinforced wood–sodium silicate composite for additive manufacturing by successfully depositing a multi-layer sample print and determining its bending strength. Full article

In recent years, efforts have focused on developing repairable, malleable, and recyclable thermoset materials to reduce the growing volume of polymer waste and extend the lifetime of existing polymeric materials. Specifically, associative covalent adaptable networks (CANs), also known as vitrimers, have received considerable attention. In this work, photopolymerizable vitrimers were prepared by combining crosslinkers containing β-amino esters in their structure with hydroxylated acrylate or methacrylate monomers, with the aim of reprocessing these materials through the activation of transesterification reactions. The network design and photopolymerization conditions were optimized to ensure the successful formation of the vitrimers. Tunable mechanical and thermal properties were achieved by varying their chemical composition. Furthermore, the reprocessing ability of these materials was confirmed through thermal treatments. Additionally, these vitrimers exhibited the ability to undergo hydrolysis in basic aqueous media, providing an alternative pathway for recycling. Full article

Hybrid materials have multifunctional capabilities that are particularly attractive for space applications in order to overcome issues related to the harshness of the environment, especially during long-duration missions. Hybridization is traditionally carried out by mixing reinforcements of different natures, such as carbon with glass/kevlar fibers, or by integrating nanomaterials into the composite structure. Promising results in terms of improved toughness, ductility, and damping ability have been recorded by placing a thermoplastic interlayer between adjacent thermosetting plies reinforced with carbon fibers. These hybrid materials have additional functionalities such as thermoformability and repairability, which make them suitable for several industrial applications. In this work, a literature review on hybrid composites is presented and experimental results on the manufacturing of hybrid carbon fiber epoxy/PEEK laminates are reported. Thermoplastic films of 25 μm and 200 μm thickness have been used as well as two manufacturing procedures. The high-thickness interlayer laminate, that was compression-molded at 250 °C, showed the highest mechanical properties with a bending strength of 340 MPa and an elastic moules of 50 GPa. The other composite, that was molded at 350 °C, exhibited reduced mechanical properties. Full article

This review paper explores the transformative potential of polymer composites and adhesives in reducing the weight of aircraft landing gear, thereby improving fuel efficiency and lowering emissions. The replacement of conventional metallic materials and mechanical fastenings with advanced thermoset/thermoplastic composites and adhesives can significantly enhance durability and performance in demanding operational environments. Unlike traditional fastening methods, the structural adhesives eliminate the weight penalties associated with mechanical fasteners, offering a lighter and more reliable solution that meets the rigorous demands of modern aerospace engineering. Furthermore, the review highlights a variety of manufacturing techniques and innovative materials, including bio-based polymers, self-healing materials, noobed composites, helicoid composites, and hybrid composites. The use of thermosets and vitrimers in adhesive bonding are presented, illustrating their ability to create robust and durable joints that enhance the structural integrity of landing gear systems. The paper also addresses current challenges, including recycling limitations and high material costs. Sustainability considerations, including the integration of self-healing materials, structural health monitoring systems, and circular economy principles, are discussed as essential for aligning the aerospace sector with global climate goals. Full article

Driven by the growing demand for sustainable materials, spent coffee grounds have emerged as a promising bio-based reinforcement in polymer composites, particularly for additive manufacturing applications. As a readily available byproduct of the coffee industry, spent coffee grounds contain cellulose, hemicellulose, lignin, proteins, and oils, making them attractive fillers for both thermoplastic and thermoset matrices. Incorporating spent coffee grounds into composites supports waste valorization, cost reduction, and environmental sustainability by transforming organic waste into functional materials. This review first examines the issue of spent coffee ground waste, addressing its environmental footprint and disposal challenges. It then explores the composition and properties of spent coffee grounds. The paper provides a comprehensive overview of composites based on spent coffee grounds for 3D printing, covering processing methods, potential applications, and current challenges in additive manufacturing. Special attention is given to the preparation and processing of these composites, including key steps such as drying, grinding, sieving, and surface modification to enhance compatibility with polymer matrices. Various additive manufacturing techniques influence the printability, processability, and mechanical performance of such composites. While spent coffee grounds offer notable sustainability advantages, challenges such as weak interfacial adhesion, moisture sensitivity, and reduced mechanical properties necessitate optimized processing conditions, surface treatments, and tailored material formulations. This review highlights recent advancements and outlines future research directions, emphasizing the need for stronger interactions between spent coffee grounds and polymer matrices, improved recyclability, and scalable additive manufacturing solutions to establish spent coffee grounds as a viable and eco-friendly alternative for 3D printing applications. Full article

Over the last few decades, polymer composites have been rapidly making inroads in critical applications of electrical storage devices such as batteries and supercapacitors. Structural supercapacitor composites (SSCs) have emerged as multifunctional materials capable of storing energy while bearing mechanical loads, offering lightweight and compact solutions for energy systems. This study investigates the functionalization of Bisphenol A-based thermosetting polymers with ionic liquids, aiming to synthesize dual-functional structural electrolytes for SSC fabrication. A multifunctional sandwich structure was subsequently fabricated, in which the fabricated SSC served as the core layer, bonded between two structurally robust outer skins. The core layer was fabricated using carbon fibre layers coated with 10% graphene nanoplatelets (GNPs), while the skin layers contained 0.25% GNPs dispersed in the resin matrix. The developed device demonstrated stable operation up to 85 °C, achieving a specific capacitance of 57.28 mFcm⁻² and an energy density of 179 mWhm⁻² at room temperature. The performance doubled at 85 °C, maintaining excellent capacitance retentions across all experimented temperatures. The flexural strength of the developed sandwich SSC at elevated temperature (at 85 °C) was 71 MPa, which exceeds the minimum requirement for roofing sheets as specified in Australian building standard AS 4040.1 (Methods of testing sheet roof and wall cladding, Method 1: Resistance to concentrated loads). Finite element analysis (FEA) was performed using Abaqus CAE to evaluate structural integrity under mechanical loading and predict damage initiation zones under service conditions. The simulation was based on Hashin’s failure criteria and demonstrated reasonable accuracy. This research highlights the potential of multifunctional polymer composite systems in renewable energy infrastructure, offering a robust and energy-efficient material solution aligned with circular economy and sustainability goals. Full article

Fiber-reinforced composites (FRCs) have emerged as transformative alternatives to traditional marine construction materials, owing to their superior corrosion resistance, design flexibility, and strength-to-weight ratio. This review comprehensively examines the current state of FRC technologies in marine deck and underwater applications, with a focus on manufacturing methods, durability challenges, and future innovations. Thermoset polymer composites, particularly those with epoxy and vinyl ester matrices, continue to dominate marine applications due to their mechanical robustness and processing maturity. In contrast, thermoplastic composites such as Polyether Ether Ketone (PEEK) and Polyether Ketone Ketone (PEKK) offer advantages in recyclability and hydrothermal performance but are hindered by higher processing costs. The review evaluates the performance of various fiber types, including glass, carbon, basalt, and aramid, highlighting the trade-offs between cost, mechanical properties, and environmental resistance. Manufacturing processes such as vacuum-assisted resin transfer molding (VARTM) and automated fiber placement (AFP) enable efficient production but face limitations in scalability and in-field repair. Key durability concerns include seawater-induced degradation, moisture absorption, interfacial debonding, galvanic corrosion in FRP–metal hybrids, and biofouling. The paper also explores emerging strategies such as self-healing polymers, nano-enhanced coatings, and hybrid fiber architectures that aim to improve long-term reliability. Finally, it outlines future research directions, including the development of smart composites with embedded structural health monitoring (SHM), bio-based resin systems, and standardized certification protocols to support broader industry adoption. This review aims to guide ongoing research and development efforts toward more sustainable, high-performance marine composite systems. Full article

The mounting global concern regarding the accumulation of plastic waste underscores the necessity for the development of innovative solutions, with particular emphasis on the incorporation of plant-based biofillers into polymer composites as a sustainable alternative to conventional materials. This review provides a comprehensive and structured overview of the recent progress (2020–2025) in the integration of plant-based biofillers into both thermoplastic and thermosetting polymer matrices, with a focus on surface modification techniques, physicochemical characterization, and emerging industrial applications. Unlike the prior literature, this work highlights the dual environmental and material benefits of using plant-derived fillers, particularly in the context of waste valorization and circular material design. By clearly identifying a current research gap—the limited scalability and processing efficiency of biofillers—this review proposes a strategy in which plant-derived materials function as key enablers for sustainable composite development. Special attention is given to extraction methods of lignocellulosic fillers from renewable agricultural waste streams and their subsequent functionalization to improve matrix compatibility. Additionally, it delineates the principal approaches for biofiller modification, demonstrating how their properties can be tailored to meet specific needs in biocomposite production. This critical synthesis of the state-of-the-art literature not only reinforces the role of biofillers in reducing dependence on non-renewable fillers but also outlines future directions in scaling up their use, improving durability, and expanding performance capabilities of sustainable composites. Overall, the presented analysis contributes novel insights into the material design, processing strategies, and potential of plant biofillers as central elements in next-generation green composites. Full article