Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends
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Abstract
Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and biobased composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fibre placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.
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