Browse Topic: Fibers

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Optimizing recycled and recyclable PET felt lightweight formulations for best acoustic insulation as poroelastic springs with minimum weight2026-01-0702To be published on 06/20/2026
For sustainability reasons, the automotive market is requesting 100% mono-material noise treatments, particularly for the end-of-life recycling without any part separation operation. But also, the OEMs require super light, highly performance insulating noise treatments for electric vehicles in order to extend vehicle autonomy. PP meltblown fiber felts present good mono-material characteristics with very good absorption, but generally not so good insulation properties behind an airtight barrier due to lack of stiffness. Moreover, these PP meltblown fiber felts are relatively expensive and not thermoformable, thus obliging to use them as 2D die-cut parts behind existing hard or soft trims classically. The optimization approach proposes to return to 100% thermoformable recycled and recyclable PET formulations blending unusual coarse mechanical specific fibers, in order to optimize the viscothermal exchanges, while maintaining good mechanical properties, with microfibers for best
Duval, Arnaud, Lei, Lei, Wilkinson, Alexandre, Delinselle, Eric
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 2 - Qualification Program for Fiber, Carbon Fiber Tape Prepreg, and Film AdhesiveAMS6885/2 (Current)6/10/2026
AMS6885/2 gives specific information about the qualification program for unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. The prepreg system shall include an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
STUD, LOCKED IN, KEY LOCKED, UNS S66286, 140 KSI/1200 °F LIGHTWEIGHT, SELF-BROACHING KEYSAS3543B (Current)6/10/2026
E-25 General Standards for Aerospace and Propulsion Systems
Design-Driven Sustainability of Automotive Components: A Comparative LCA from Conventional to Metal and Composite Additive Manufacturing2026-37-00376/9/2026
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional sheet metal fabrication and finishing operations of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in Polyethylene Terephthalate Glycol with Carbon Fiber (PETG-CF) are compared to conventional
Dalpadulo, Enrico, Russo, Mario, Apté MD, Raphaëlle, Leali, Francesco
Improvement of rCF Behaviour through the Introduction of NF2026-37-00396/9/2026
This study investigates the structural improvement of recycled carbon fibre composites through hybridisation with continuous flax fibres to address sustainability concerns and performance limitations. Recycled carbon fibres, while environmentally beneficial, suffer from short, randomized orientations and lower mechanical properties limiting their application beyond decorative uses. This research explores whether incorporating unidirectional flax fibres can enhance rCF behaviour for structural applications. Six hybrid composite layup variants and two plain composites were manufactured using cold compression moulding with Ampro Bio Resin. Each hybrid configuration comprised eight layers, divided into four layers of recycled carbon and four layers of flax fibres oriented at 0°. Complete mechanical characterization was performed following ISO standards for tensile (ISO 527), flexural (ISO 178), and impact (ISO 179) testing. Results demonstrated significant performance improvements in
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
European Researchers Develop Self-Healing Composite Material for Spacecraft26AERP06_116/1/2026
Researchers from CompPair and the European Space Agency have developed a new composite material for spacecraft with an embedded healing agent. European Space Agency, Paris, France Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company Com&Sens have partnered with the European Space Agency (ESA) to modify their self-healing carbon fiber product for use in space transportation. Project Cassandra - an abbreviation for Composite Autonomous Sensing and Repair - includes sensors and a heating element within a composite carbon-fiber material, allowing spacecraft to autonomously repair initial stages of damage.
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High-Performance Nanocomposites2026-26-07326/1/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In this study, injection moulding was used to develop a biodegradable polymer PLA composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet, which is sustainable. Materials need machining as secondary operation that required joining. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed with Taguchi's design (L9 orthogonal array). Surface roughness (SR) and delamination factor (Fd) were taken as outputs, while spindle speed (SS), feed rate (FR), and drill diameter (DD) were the inputs. Drilling studies were performed on a single vertical machining center (VMC). ANOVA identifies that the FR had the most decisive influence on SR (F=559.24, p=0.001785), followed by DD and SS. FR is the dominant contributor to Fd (F=379, p=0.00263), followed by SS and DD. At low SS and high
Senthilkumar, N.
Conceptual Design of CFRP Sandwich Structures Interfacing Cryogenic Tankages in Rockets2026-26-07616/1/2026
The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while
Bhalerao, Sandesh Popat, Gupta, Yogesh Kumar, Madhukumar, P.
Evaluation of Thermal Behaviour of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-07546/1/2026
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
From Racing Car to Rocket Tank26AERP06_086/1/2026
German startup Blackwave is building carbon parts for rocket tanks. Technical University of Munich, Munich, Germany Carbon fiber has become indispensable in high-performance industries such as automotive engineering and aerospace. It's lightweight, extremely durable, and can be shaped in almost any way. The start-up Blackwave, founded at the Technical University of Munich (TUM), specializes in this versatile composite material. What began with custom components for sports cars and aircraft has evolved into the development of high-pressure tanks for space applications. As is so often the case in engineering, a small detail determines technological progress. In the case of rockets, it is the high-pressure tanks that are specially designed for the fuel systems. As rockets are designed to be as light as possible, they lose structural stability when the fuel tanks, known as primary tanks, are emptied. A trick is used to counteract this: alongside fuel combustion, noble gases are released
Assessment of Injection Gate Location Effects on Mechanical Performance of Short Fiber Reinforced Plastic Components Using Digimat2026-26-07466/1/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of failure under
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
Development of Graphene Filled Polypropylene Nanocomposite for Aerospace Application2026-26-07396/1/2026
Polypropylene, a commodity plastic, is the semi-crystalline thermoplastics widely used in high volume for general purpose application. Polypropylene is the macro molecules of soft and weak backbone, which by reinforcement of fillers in different forms such as fiber, spheroids, nanotubes, flakes, etc., can influence its mechanical, thermal, electrical, creep resistance, and flame resistance properties for use in aerospace applications. Currently, polycarbonate and nylon plastics are used in aerospace applications, however, they are expensive compared with polypropylene. In this thesis, efforts are put to study the effect of reinforcement fillers in the properties of polypropylene composite, primarily the mechanical and flammability properties. The matrix element, polypropylene co polymer and reprocessed polypropylene blended in equal ratio, are coupled with the dispersing phases such as graphene, mica, fumed silica, and polydimethylsiloxane polymer. Effect of graphene as reinforcing
Govindaraju, Parthasarathy
Investigating the Electrochemical Corrosion Behaviour of Bamboo Fiber-Marine Waste Reinforced Polymer Matrix Hybrid Composites for Light Weight Applications2026-26-07336/1/2026
This study investigates the corrosion behaviour of bamboo-crab shell fortified polymer matrix hybrid composites. Three unique hybrid composites were created utilizing the hand layup approach, with epoxy as the matrix material, 15 wt.% bamboo fibers (BFs), and varying quantities (3, 6, and 9 wt. %) of marine resource crab shell (CS). Electrochemical corrosion tests were utilized to evaluate the hybrid sustainable composite's corrosion behaviour. The testing results reveal that epoxy-15 wt.%BF-6 wt.%CS (P2) composite has better corrosion resistance than epoxy-15 wt.%BF-3 wt.%CS (P1) and epoxy-15 wt.%BF-9 wt.%CS (P3). A potentiodynamic polarization test revealed an icorr value roughly five times lower than P1 and three times lower than P3 composites. Furthermore, the Nyquist plot obtained from the EIS study revealed that the P2 composite has a larger capacity loop than the P1 and P3 composites. It also indicates that the P2 composite is more resistant to corrosion than the other two. The
Senthilkumar, N., Srinivasan, D, G, Perumal, Balakrishnan, Deepanraj
Improvement of Mechanical Properties of Synthetic Fiber Reinforced Composites through Addition of Graphene Oxide2026-26-07536/1/2026
Unmanned Aerial Vehicles (UAVs) demand structural materials that are lightweight, strong, impact-resistant, and durable in diverse environments. The synthetic fiber reinforced polymer composites have varying mechanical performance depending on the fiber matrix interfacial properties. This research analyzes the influence of Graphene Oxide (GO) nano fillers on mechanical properties of composites. Firstly, the epoxy resin was modified by incorporating different weight percentage of Graphene Oxide. This resin was used to make an composite laminate using different materials (Carbon, Glass and combination of these fibers). Then the composites were put through the tensile, compression, flexural tests. The synthetic fiber reinforced polymer composites have a significant improvement in mechanical properties due to the addition of Graphene Oxide.
Manoharan, Dinesh, Langford, Peter, M.K., Padmanabhan, R, Prithviraj, Rajkumar, Subbiah, Karthikeyan, Ravikumar, Veeramuthu, Balasubramaniyan, Gunaseelan, John, T, Thangaraj
Advanced Composites Prepreg - Nominal 250 °F (121 °C) Cure - 12K Tow Carbon Fiber and Epoxy Resin, Plain Weave FabricAMS3914B (Current)5/15/2026
The intent of this specification is for the procurement of plain weave fabric epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
AMS P17 Polymer Matrix Composites Committee
Research on the Friction Performance of EVA Insulating Mats for Live Working in Smart Grids2026-99-07145/15/2026
Live-line operation is a critical technique for maintaining the reliability and continuity of power supply in modern distribution networks. Insulating mats serve as essential protective equipment during such operations by providing both electrical insulation and mechanical shielding. In practical service conditions, insulating mats are subjected to repeated mechanical contact and friction against conductors, metallic fittings, and ground surfaces, which progressively deteriorates their surface integrity and compromises operational safety. Current performance standards for insulating mats emphasize dielectric and tensile properties, while tribological durability remains unaddressed. In this study, an EVA – PA6 composite film fabricated via the tape casting method was selected as the representative outer insulating layer of insulating mats. Reciprocating friction tests were conducted using an SDR339 abrasion tester to evaluate the effects of normal load and sliding speed on wear behavior
Sun, Xin, Wen, Libin, Kou, Hanpeng
Advanced Composites Prepreg - Nominal 250 °F (121 °C) Cure - Carbon Fiber and Epoxy Resin, Unidirectional TapeAMS3960B (Current)5/15/2026
The intent of this specification is for the procurement of carbon fiber epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
AMS P17 Polymer Matrix Composites Committee
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 5 - Material Specification for Unidirectional Carbon Fiber Tape Epoxy Prepreg for Repair and Film Adhesive for Repair, 120 to 145 °C (250 to 290 °F) CuringAMS6885/5 (Current)5/7/2026
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Anisotropic Mechanical Property Simulation of Fiber Reinforced PEEK Using Composite Theory and Comparison to Experimental Results2026-01-02564/7/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing2026-01-02574/7/2026
Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight advantages of composite materials, making it a promising approach for lightweight automotive components. The mechanical performance of fiber-reinforced composites is strongly influenced by fiber orientation, which highlights the importance of optimization methods that can effectively exploit anisotropic behavior. Existing FRAM optimization research has focused primarily on structural performance and has given limited attention to manufacturability challenges. This gap is significant, as overhangs and the resulting need for support structures can substantially increase print time, material consumption, and production cost, restricting broader industrial uptake. This research introduces a multi-objective topology optimization framework that incorporates Design for Additive Manufacturing (DfAM) principles by minimizing both structural compliance and
Wotten, Erik, Kim, Il Yong
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-00212/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a
Raja, K., Senthil Kumar, M.S.
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability
Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research26AERP02_082/1/2026
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace26AERP02_012/1/2026
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Design and Development of a Lightweight Aluminium Cascade System for Type IV COPVs for Stationary and Mobile Applications2026-26-04851/16/2026
The global push for clean energy has made hydrogen a central element in decarbonizing transport, industrial processes, and energy systems. Effective hydrogen storage and distribution are critical to supporting this transition, and type IV Composite Overwrapped Pressure Vessels (COPVs) have emerged as the preferred solution due to their lightweight, high pressure capacity, hydrogen embrittlement and corrosion resistance. However, the cascade infrastructure used to house and transport these vessels has lagged behind in innovation. Steel-based cascades, while strong, are heavy prone to corrosion, and unsuitable for mobile deployment. This paper introduces a custom designed aluminium cascade system offering a 65% weight reduction while maintaining structural integrity and safety. Designed for mobile use, the system features modularity, better damping, and enhanced corrosion protection. The paper outlines design methodology, material selection, fabrication process, and comparative
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
Development of Sustainable Textile Solutions Using Recycled and Bio-Based Materials for Automotive Soft Trims2026-26-02361/16/2026
The rising importance of sustainability in the automotive sector has led to increased interest in circular and environmentally responsible materials, particularly for plastic trims parts, both interior and exterior. This study focuses on developing textile solutions using recycled polyethylene terephthalate (r-PET) sourced from post-consumer plastic waste, along with bio-based fibres such as bamboo. These materials made into woven and knitted fabrics are studied to suit different vehicle interior applications. r-PET textiles show promising strength, aesthetic appeal, and durability performance. Bamboo fabrics are known for their natural antimicrobial properties and enhanced breathability. Extensive testing is performed to validate explored sustainable materials performance against key automotive requirements. With this study, we gain an understanding of the performance of variedly sourced sustainable raw materials for automotive specific textile applications by different manufacturing
Deshpande, Sanjana, Borgaonkar, Subodh
Electronic Fiber Provides Stretchable SensingTBMG-544211/1/2026
EPFL researchers have engineered a fiber-based electronic sensor that remains functional even when stretched to over 10 times its original length. The device holds promise for smart textiles, physical rehabilitation devices, and soft robotics.
Advances in Fiber Laser Welding for E-Mobility ManufacturingTBMG-544331/1/2026
High-power fiber lasers have become increasingly indispensable tools in automotive manufacturing over the past two decades. They are now widely deployed in welding and brazing applications for body-in-white, powertrains, engine components, and more.
Influence of the PTFE on the Tribological and Mechanical Properties of a Fiber-Reinforced Polyphthalamide2025-36-022112/18/2025
Materials science and engineering are essential for advancing energy-efficient mechanical systems through lightweight structures and friction reduction. Among engineering polymers, polyphthalamides (PPA) are widely used for their superior thermochemical and mechanical properties. This study investigates the influence of polytetrafluoroethylene (PTFE) on the mechanical and tribological performance of a commercial polymer matrix composite (PMC) reinforced with 30wt% glass fiber. Self-lubricating composites were manufactured by injection molding with PTFE contents ranging from 0-15 wt%. Density was measured using Archimedes’ method. Mechanical properties were measured through ISO 527 tensile testing, while tribological behavior was evaluated using ball-on-flat reciprocating tests under 189N (630 MPa), 2 H frequency, and 10 mm strokes for 60 minutes, employing a 10 mm diameter AISI 52100 steel sphere as counter-body. Friction coefficient (COF) was monitored throughout testing, and wear
Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
Mechanical Tensile Behavior of Polyester Composites with Addition of Banana and Sugarcane Fibers2025-36-015412/18/2025
Polymer composites with the addition of natural fibers have gained prominence as a sustainable and technically viable alternative to conventional synthetic materials, especially in applications that require a balance between mechanical performance and environmental responsibility. This study evaluated the mechanical behavior of composites produced with plant fibers from banana (Musa sapientum) and sugarcane (Saccharum officinarum L.), both sourced from the northern region of Brazil. The fibers, used in their natural state without chemical treatment, were cut to a uniform length of 5 mm for standardization. The polymer matrix used was unsaturated terephthalic polyester resin, pre-accelerated and catalyzed with methyl ethyl ketone peroxide (MEKP). The molding of test samples was performed manually in silicone molds, according to ASTM D638 specifications, to ensure repeatability and comparability of results. The mechanical tests revealed that the composites made with sugarcane fibers had
Santos Borges, Larissa, Dias, Roberto Yuri Costa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Natural Fibers Applied in the Automotive Industry in Brazil: A Review2025-36-017012/18/2025
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and
Dias, Roberto Yuri Costa, Santos Borges, Larissa dos, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor de, Silva de Mendonça, Alian Gomes da, Fujiyama, Roberto Tetsuo
Natural Fiber Composites with Nanomaterials: A Sustainable Alternative to Metals in the Automotive Industry2025-36-004012/18/2025
This paper analyzes the potential of combining natural fibers with nanomaterials to develop advanced composites for automotive sector applications, providing a sustainable alternative to parts traditionally produced with metallic materials. The metallic alloy in the automotive industry is widely used in vehicle manufacturing, but faces significant challenges, such as high production costs, high weight, susceptibility to corrosion, and rigorous recycling processes. Natural fibers stand out for favorable mechanical properties, low cost, low weight, and eco-friendly material, making promising alternatives to metals and synthetic fibers. The combination of natural fibers and nanomaterials creates composites with improved mechanical and thermal, reducing any limitations inherent to natural fibers. Therefore, composites combined, called hybrid, have a high potential for use in various automotive components, such as in structural and non-structural applications. This study also analyzes the
Corrêa, Karytha, Cabral, Gabriel, Santiago, Marcelo, Veloso, Verônica, Chaves, Matheus
Review of Through-the-Thickness Reinforcement Technologies Applied to Aircraft CFRP Composites2025-99-035512/17/2025
Carbon fiber-reinforced polymer (CFRP) composites are widely used in aircraft structures for weight reduction due to their high specific strength and modulus. However, their weak interlaminar properties lead to high sensitivity to out-of-plane loads such as impact, making them prone to delamination damage, which threatens flight safety. To enhance interlaminar performance, through-thickness reinforcement technologies, particularly Z-pinning and stitching, have become key research focuses. This paper systematically reviews the manufacturing processes, structural mechanical characteristics, and application progress in aerospace structures of these two mainstream through-thickness reinforcement technologies. Research shows that Z-pintechnology, by implanting metal or CFRP pins, and stitching technology, by sewing multiple fabric layers with fiber threads, both effectively bridge interlaminar cracks, significantly improving the impact resistance of composites. However, the implantation
Cui, Bo, Zhang, Yongjie, Zhang, Chuzhe, Jin, Tao
Mechanical System Innovation for Next-Generation Electric Vehicles: Lightweight and Energy Recovery Co-Design2025-99-033412/17/2025
Aiming at the technical bottlenecks of electric vehicles (EVs) in terms of range, energy efficiency and thermal management, this paper proposes an innovative mechanical system design scheme that integrates lightweight materials, topology-optimised structure and mechatronic energy recovery. Through multi-physics simulation and experimental verification, the coupling mechanism between mechanical design and electrochemical performance is revealed, providing theoretical support for the development of energy-efficient electric vehicles. The research adopts a hybrid structure of carbon fiber reinforced polymer (CFRP) and aluminum alloy, and combines it with topology optimization technology to achieve lightweight (18% weight reduction) and improved impact resistance (40% improvement in energy absorption) of the battery box; the design of a bimodal energy recovery system integrating flywheel energy storage and magnetorheological damper, which can achieve an energy recovery efficiency of 82.7
Xu, Nanxin, Song, Ziyang, Han, Qiyu, Chen, Xiaoxian, Miao, Zhengchen, Song, Jinlong
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace ApplicationsAMS6891A (Current)12/16/2025
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Automated fiber placement with Ramy Harik25AUTP12_0912/1/2025
AFP can build complex, lightweight structures, but cost concerns keep its use in the automotive industry to a minimum. For now, anyway. Ramy Harik, a Fulbright alumnus and director of the Clemson Composites Center, is pushing the boundaries of manufacturing with his latest book, Automated Fiber Placement: Status, Challenges, and Evolution coauthored with Alex Brasington. The book, published by SAE in June of 2025, serves as a comprehensive guide to automated fiber placement (AFP), a cutting-edge technology crucial for building complex, lightweight structures in the aerospace and automotive industries. The book aims to offer a thorough understanding of AFP's transformative potential for students, engineers, and industry professionals. The book synthesizes a decade of research, explaining how AFP supports the rise of advanced air mobility and sustainable structures for commercial and defense aircraft, space habitats, and beyond.
Blanco, Sebastian
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 35, Class 1, Grade 191AMS6891/1A (Current)12/1/2025
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy/Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 40, Class 1, Grade 196, Style 6K-PWAMS6891/2A (Current)12/1/2025
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
How Carbon Fibers Can Help Manufacture Li-ion BatteriesTBMG-5427412/1/2025
Oak Ridge National Laboratory (ORNL) researchers have overcome a barrier to using a more affordable, dry process for manufacturing the Li-ion batteries used in vehicles and electronic devices. The resulting batteries provide greater electricity flow and reduced risk of overheating.
SAE TOMORROW TODAY - Conquering the Australian Outback with Solar Power1354411/21/2025
What does it take to race 3,000 kilometers across the unforgiving Australian Outback powered only by the sun? Listen in as we sit down with Martijn Boonen, Electrical Engineer & Driver, Brunel Solar Team, and Tony Mathew, Global Market Manager, Teijin Aramid, to reveal the secrets behind their record-breaking solar car victory at the 2025 Bridgestone World Solar Challenge. Discover how cutting-edge engineering, relentless teamwork, and innovative sustainable materials came together to conquer extreme heat, torrential rain, and fierce competition. Hear firsthand how the Brunel Solar Team's winning mentality led to their eighth global win, and how circular fiber tire technology proved that sustainability and high performance can go hand-in-hand. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in
Patterson, Lori
Integrating Self-Hydraulic Jacks Under the Chassis for Off-Road Vehicles, and Utility Task Vehicles2025-28-026411/6/2025
A futuristic vehicle chassis rendered in precise detail using state-of-the-art CAD software like Blender, Autodesk Alias. The chassis itself is sleek, low-slung, and aerodynamic, constructed from advanced materials such as high-strength alloys or carbon-fibre composites. Its polished, brushed-metal finish not only exudes performance but also emphasizes the refined form and engineered details. Underneath this visually captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks are situated adjacent to the four shock absorber mounts. These jacks are designed to lift the chassis specifically at the tyre areas, and the total vehicle, ensuring that underbody maintenance is efficient and that, in critical situations, vital adjustments or emergency lifts can be performed quickly and safely. The design also incorporates an intuitive control system where the necessary buttons are strategically placed to optimize driver convenience. Whether
Gogula, Venkateswarlu
Nanofibers Yield Stronger, Tougher Carbon Fiber CompositesTBMG-5412111/1/2025
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
How AI Can Find the Next Groundbreaking PolymerTBMG-5412511/1/2025
Nylon, Teflon, Kevlar. These are just a few familiar polymers — large-molecule chemical compounds — that have changed the world. From Teflon-coated frying pans to 3D printing, polymers are vital to creating the systems that make the world function better.
Composite Materials Handbook Volume 3 - Revision HR-64010/16/2025
The third volume of this six-volume compendium provides methodologies and lessons learned for the design, analysis, manufacture, and field support of fiber-reinforced, polymeric-matrix composite structures. It also provides guidance on material and process specifications and procedures for using the data that is presented in Volume 2. The information provided is consistent with the guidance provided in Volume 1, and is an extensive compilation of the current knowledge and experiences of engineers and scientists from industry, government, and academia who are active in composites. The Composite Materials Handbook, referred to by industry groups as CMH-17, is a six-volume engineering reference tool that contains over 1,000 records of the latest test data for polymer matrix, metal matrix, ceramic matrix, and structural sandwich composites. CMH-17 provides information and guidance necessary to design and fabricate end items from composite materials. It includes properties of composite
CMH-17
FibreCoat’s New Radar-Absorbing ‘Stealth’ Fiber Reinforced Composites for Spacecraft, Aircraft and TanksTBMG-537539/1/2025
FibreCoat, the German materials startup, has developed a groundbreaking fiber reinforced composite that is capable of making aircraft, tanks and spacecraft invisible to radar surveillance.
FibreCoat's New Radar-Absorbing ‘Stealth’ Fiber Reinforced Composites for Spacecraft, Aircraft and Tanks25AERP09_069/1/2025
FibreCoat, the German materials startup, has developed a groundbreaking fiber reinforced composite that is capable of making aircraft, tanks and spacecraft invisible to radar surveillance. The company was officially founded in Aachen, Germany, in 2020, however its core founding team first began developing new approaches to the use of materials that make commercial and military vehicles invisible to radar as back as 2014. FibreCoat is known for inventing a novel technology to coat metals and plastics onto fibers, thus combining the properties of the fibers and the coating material, during the fiber-spinning process.
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