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Reference - Advances in lightweight composite structures and manufacturing technologies: A comprehensive review

From CKN Knowledge in Practice Centre
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Type Journal
Title Advances in lightweight composite structures and manufacturing technologies: A comprehensive review
Abstract

Abstract

The field of lightweight composite structures has witnessed significant advancements in recent years, revolutionizing numerous industries through their exceptional combination of strength, weight reduction and versatility. This review paper provides a comprehensive and in-depth analysis of these ground breaking materials. It elucidates fundamental concepts of lightweight composite structures, exploring their composition, classification, physical and mechanical properties as well as recent strides in their engineering applications. Crucially, this review highlights the recent progress and developments of lightweight composite materials. From aerospace to automotive, from construction to sporting goods, these advanced materials are transforming various industries by combining strength with reduced weight. Emphasizing the role of lightweight composites in energy-efficient systems, the paper underscores their significance in resource optimization and sustainable engineering practices. A detailed examination of various types of composites, such as polymer matrix composites, ceramic matrix composites and metal matrix composites, will be presented, highlighting their specific advantages and applications. Moving forward, the review delves into the diverse fabrication methods employed to create these advanced materials. This comprehensive paper serves as a valuable resource for researchers, engineers, and industry professionals seeking to capitalize on the benefits of lightweight composite materials. By presenting a holistic view of composites' classification, properties, and recent advancements, this study fosters innovation and propels the integration of lightweight composite materials into diverse engineering applications, ultimately driving progress towards a more efficient, sustainable, and technologically advanced future.

Accessed 2026-03-16
Authors
  • Phiri, Resego
  • Mavinkere Rangappa, Sanjay
  • Siengchin, Suchart
  • Oladijo, Oluseyi Philip
  • Ozbakkaloglu, Togay
Date 2024-11-15
Issue 21
Pages e39661
Publisher Elsevier
Journal Heliyon
Volume 10
Websites
DOI 10.1016/j.heliyon.2024.e39661
ISSN 24058440
Keywords Applications, Classification, Fabrication, Lightweight composites
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Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

The continuous material phase that binds the reinforcement together, maintains shape, transfers load, protects the reinforcement from environment and damage, and provides the composite support in compression.

Desirable characteristics:

  • Moisture/chemical resistance
  • Low density
  • Processability
Retrieved from "https://compositeskn.org/KPC/index.php?title=Reference:6e790f30-e9df-3792-8b11-cb9668a79b37&oldid=7372"
CKN KPC logo

Welcome

Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:

Understanding Composites Processing

The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:

The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.

The relationship between material, shape, tooling & consumables and equipment during a process step


Interrelationship of Function, Shape, Material & Process

Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:

The relationship between function, material, shape and process


Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


Workflows

The KPC's Practice and Case Study volumes consist of three types of workflows:

  • Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
  • Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
  • Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.

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