Composite materials were all the rage ten years ago, but the news coming through about them is less common than it used to be. Even so, the underlying science and technology is developing quickly, and the world is likely to see more advanced technologies in the years to come.
The late 2020s and early 2030s should be a testament to the impact of all of this research and development that has gone on over the last 50 years. Many material technologies are now coming to fruition and finding real commercial applications that benefit regular people.
Self-healing composites
One of the most exciting areas of research and development is the improvements that have occurred recently in self-healing composites. Many of these breakthroughs have happened recently, even in 2026, thanks to fibre reinforcement, which allows many composites to repair themselves up to 1,000 times.
The idea behind self-healing composites is to use a 3D-printed thermoplastic impregnated with healing agents between various carbon-based layers. When the material detects a crack, an electric current melts the agent and then allows new material to flow into the space that’s being created, effectively healing it. This repair process can’t happen infinitely, but it can happen many times, even in the same place, because of how the agent material is distributed throughout the composite.
The goal is to extend the life of aircraft wings and turbine blades. These are expensive to replace and difficult to retrofit, even onto equipment that’s already functioning well. The new self-healing composite materials could allow many of these structures to last for centuries, reducing the risk of material supplies running out.
AI-driven data-intelligent manufacturing
Another development in the area of composites is the use of AI-driven data-intelligent manufacturing. The idea is to use AI and data-integrated systems to simulate the entire life cycle of specific products and materials, enabling them to last longer.
For example, physics-informed neural networks can now predict things like the optimal heat and pressure for manufacturing specific components or cutting parts. This means that companies no longer have to guess or use trial and error to arrive at the right solution. Much of the design is derived from first principles, and production cycles can also be reduced by up to 30% by minimising energy consumption. This increases margins and allows firms to improve their competitiveness over time.
Structural health monitoring
Many composites are now being given their own nervous systems so that they can detect where problems exist, similar to vehicles with sensors or other sophisticated products that require constant monitoring. The idea is to integrate fibre optic sensors and acoustic emission systems into the design to see into the various layers and laminate them one on top of the others. This way, the material itself can feel where it has a problem and then correct it.
The idea of the first phase of development is to use sensors and IoT technology to generate digital twins. This means that even if microscopic damage occurs, it’s possible for the material to improve itself quickly.
High-performance biocomposites
Many companies are now exploring the realm of high-performance biocomposites. The idea is to take the best that nature has to offer and then leverage this to create materials that are more robust and suitable for specific applications, similar to what firms like Connova AG do.
High-performance biocomposites are due to skyrocketing popularity over the coming years. Tech breakthroughs have solved many of the issues that used to be problematic when using biocomposites, like the moisture problem associated with hemp and flax-based products. Now many firms are developing advanced bio-based resins, which have a tighter structure and reduce the risk of moisture penetration.
Many auto makers are already using high-performance biocomposites to make semi-structural parts. This means they’re able to improve the quality of cabins and provide their customers with eco-friendly designs.
Volumetric and multi-material 3D printing
Lastly, we’re seeing the development of so-called volumetric and multi-material 3D printing. The idea is to use 3D printers to create pieces of material out of different substances at the same time, interweaving them together on a microscopic level. Traditional 3D printing went layer by layer, which was challenging, whereas volumetric additive manufacturing uses ultrasound to solidify it. You can solidify entire structures all at once. Multinozzle printers are also becoming available, and the size of the printer heads is decreasing, allowing for the creation of more accurate structures.
Overall, the impact of composite materials is likely to be enormous over the coming years. Many companies are investing heavily in R&D, so there should be real-world benefits arriving soon.
Photo by Thomas De Giorgio on Unsplash
