Sohail Ali , Mayur Jiyalal Prajapati , Yung Chuan Kuo , Bing Jen Hsieh , Cho-Pei Jiang , Jeng-Ywan Jeng
{"title":"A dual-mode activated, 3D-printable composite foam resin for rapid microwave and thermal expansion","authors":"Sohail Ali , Mayur Jiyalal Prajapati , Yung Chuan Kuo , Bing Jen Hsieh , Cho-Pei Jiang , Jeng-Ywan Jeng","doi":"10.1016/j.coco.2025.102605","DOIUrl":"10.1016/j.coco.2025.102605","url":null,"abstract":"<div><div>In this study, a dual-mode activated 3D printable composite foam resin is formulated that rapidly expands under both thermal and microwave energy. This composite resin consists of UV-curable aliphatic urethane acrylate oligomers and monofunctional acrylate monomers-based resin along with expandable microsphere and fumed silica nanoparticles. Vat photopolymerization process (VPP) is used to fabricate a stable crosslinked matrix that accommodates volumetric expansion in the subsequent steps of thermal and microwave heating. Microwave heating of the samples attains full expansion in under 2 min, compared to 30 min with thermal heating. The degree of curing reached 70.9 % for microwave activation and 36.8 % for thermal, while both the methods exhibited identical density (137 kg/m<sup>3</sup>) but with noticeable differences in internal pore morphology. Thermally foamed samples exhibited higher compressive modulus (6.69 MPa), specific energy absorption (SEA 6.18 J/g), and yield strength of (1.08 MPa) whereas microwave-foamed samples showed higher energy absorption in tension (SEA 1.26 J/g) and faster processing. ANSYS LS-DYNA was used to validate the experimental compressive behavior of the expanded foam activated by both methods. This dual-energy-responsive foam resin enables the digital fabrication of lightweight foams with tunable morphology and mechanical properties. Potential applications of such materials include wearable impact protection, such as helmet liners, and customized energy-absorbing components for aerospace, automotive, and defense sectors.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102605"},"PeriodicalIF":7.7,"publicationDate":"2025-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Héctor Lobato , Ignacio Trojaola , Felipe Garitaonandia , Jon Haitz Badiola , Pablo Larreategi , Aizeti Burgoa
{"title":"Smart design of thermoplastic vulcanizate products: Linking process to performance via interpretable machine learning","authors":"Héctor Lobato , Ignacio Trojaola , Felipe Garitaonandia , Jon Haitz Badiola , Pablo Larreategi , Aizeti Burgoa","doi":"10.1016/j.coco.2025.102608","DOIUrl":"10.1016/j.coco.2025.102608","url":null,"abstract":"<div><div>Thermoplastic vulcanizates (TPVs) are promising materials for various industrial applications due to their lightweight nature, recyclability, design flexibility, and ease of injection molding. A key challenge in designing TPV-based components is controlling and predicting the local stress and plastic strains induced during processing. This study examines the application of machine learning (ML) to identify key injection molding parameters that influence TPV mechanical properties and to predict stress–strain behavior for optimized component design. A full factorial design of experiments (DOE) was conducted to produce 32 TPV plaques under varying conditions. Dumbbell-shaped specimens were extracted from the middle and end regions of each plaque in both transverse and longitudinal flow directions. Cyclic tensile tests were performed to measure two target properties: the stress at 30% strain and the plastic strain, or permanent set, after unloading from the 30% strain cycle, yielding a dataset of 128 samples. ML models of varying complexity and interpretability (decision trees, random forests, gradient boosting, and neural networks) were rigorously evaluated using cross-validation and group-splitting. Given multicollinearity among features, optimal feature sets were selected, simultaneously maximizing accuracy and interpretability. While neural networks achieved the highest predictive performance, decision trees provided full interpretability, a valuable trade-off for industrial adoption. Feature importances and SHapley Additive exPlanations (SHAP) revealed that dosage volume and specimen orientation with respect to the flow direction are the most influential parameters. These findings highlight the potential of data-driven approaches for linking processing parameters to mechanical properties, enabling more efficient TPV-based component design and development strategies.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102608"},"PeriodicalIF":7.7,"publicationDate":"2025-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262725","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Development and characterization of calcium carbonate reinforced PLA composite filament for sustainable fabrication of TPMS and FG-TPMS structures using FFF","authors":"Kishore Ravikumar , Gurusamy Pathinettampadian , Murugan Vellaisamy , Lokesh kumar J","doi":"10.1016/j.coco.2025.102606","DOIUrl":"10.1016/j.coco.2025.102606","url":null,"abstract":"<div><div>This study concentrates on the development of sustainable bio-composites for Additive Manufacturing (AM) using Fused Filament Fabrication (FFF). Polylactic acid (PLA) reinforced with eggshell powder at an optimized composition of 15 wt% was extruded into composite filaments and used to fabricate Triply Periodic Minimal Surface (TPMS) and Functionally Graded TPMS (FG-TPMS) structures. Compression tests (ASTM D1621-10) and microstructural analyses were carried out to evaluate compressive strength, stiffness, and energy absorption behaviour. The results revealed that eggshell-PLA TPMS structures possess an enhanced load-bearing capability, controlled deformation, and superior energy absorption behaviour. These findings bring to limelight about the potential of eggshell-PLA composites as lightweight, high-performance, and environmentally friendly materials for applications in automotive crash absorbers, aerospace interior components and biomedical implants such as bone scaffolds and orthotic supports.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102606"},"PeriodicalIF":7.7,"publicationDate":"2025-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262726","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Kailun Li , Yixing Qian , Shaoran Cheng , Zhenyu Yang , Zixing Lu
{"title":"A deep learning-assisted Micro-CT fusion approach for high-fidelity braided composites RVE modeling and mechanical performance analysis with geometric-dispersion considerations","authors":"Kailun Li , Yixing Qian , Shaoran Cheng , Zhenyu Yang , Zixing Lu","doi":"10.1016/j.coco.2025.102603","DOIUrl":"10.1016/j.coco.2025.102603","url":null,"abstract":"<div><div>This study combines Micro-CT scan data for high-resolution 3D data acquisition with deep learning-based image preprocessing to achieve a high-precision representative volume element (RVE) of 3D four-directional braided composites (3D4DCs). By integrating Cycle Generative Adversarial Network (CycleGAN) for image enhancement and YOLOv8 for pixel-level segmentation, this method enables comprehensive and automated analysis of Micro-CT scan data, outperforming traditional thresholding, thereby laying the groundwork for high-fidelity numerical simulation. A statistical mean–based reconstruction method is proposed to reconstruct a high-fidelity 3D4DCs RVE model. Numerical results demonstrate significantly improved predictive accuracy, with simulated stress-strain curves showing close alignment with experimental data. It is found that the pressurization process during curing significantly alters the fiber orientation distribution within the composite material, transforming the material from the originally designed approximately transverse isotropy to orthotropic anisotropic composite material. Furthermore, geometric uncertainty systematically reshape the mechanical response landscape: each deformation mode activates distinct micro-structural feature, causing the same spatial variability to impact elastic constants with notably different intensity. As a result, certain properties exhibit high sensitivity while others remain largely unaffected, implying that the degree of dispersion is inherently property-specific. This work not only establishes a “geometry-property” relationship for braided composites but also introduces a novel deep learning-assisted modeling method. The proposed methodology significantly enhances the accuracy and reliability of braided composites simulations, providing considerable potential for high-precision assessment of braided composites in engineering applications.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102603"},"PeriodicalIF":7.7,"publicationDate":"2025-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262724","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhengyan Zhang , Shijie Wei , E. Cheng , Fan Bu , Yicong Guo
{"title":"Anisotropic composite sensor based on CF/CB for strain and pressure sensing","authors":"Zhengyan Zhang , Shijie Wei , E. Cheng , Fan Bu , Yicong Guo","doi":"10.1016/j.coco.2025.102602","DOIUrl":"10.1016/j.coco.2025.102602","url":null,"abstract":"<div><div>Flexible sensors have made significant progress in wearable devices, however traditional uniaxial sensors still face huge challenges in distinguishing three-dimensional (3D) motions. In this paper, a cost-effective and high-performance composite sensor based on carbon fiber (CF) in conjunction with the modulus cliff region (MCR) is proposed to distinguish strain direction and detect pressure. The composite sensor consists of two identical strain sub-sensors stacked orthogonally, with pressure-sensitive microstructures uniformly distributed between the two layers. The composite sensor exhibits remarkable anisotropic strain sensing performance with gauge factors (GF) of 46.4 and −1.2 corresponding to loads applied along the carbon fiber (ACF) direction and perpendicular carbon fiber (PCF) direction, respectively. Meanwhile, the composite sensor demonstrates an excellent pressure sensing performance with a sensitive capacitance response (S = 0.15 kPa<sup>−1</sup>), outstanding stability (2000 cycles) and tiny pressure (75 mg) detection capability. In addition, the composite sensor shows application prospects in posture detection, muscle state recognition, and pulse monitoring, which provides new ideas and methods for future smart health devices.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102602"},"PeriodicalIF":7.7,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262729","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qunyang Li , Fayong Li , Hailu Liu , Chen Li , Dong Xie , Kanstantsin Livanovich , Zlata Livanovich
{"title":"Functionalized MXene as a multifunctional crosslinker for reinforced novel waste PET-depolymerized monomer-based polyurethane composites with electrical conductivity and electromagnetic shielding effect","authors":"Qunyang Li , Fayong Li , Hailu Liu , Chen Li , Dong Xie , Kanstantsin Livanovich , Zlata Livanovich","doi":"10.1016/j.coco.2025.102598","DOIUrl":"10.1016/j.coco.2025.102598","url":null,"abstract":"<div><div>The construction of functional crosslinked polyurethane composites based on the depolymerized monomer bis(2-hydroxyethyl) terephthalate (BHET) from abandoned PET can achieve high-value application of BHET. Herein, polyurethane composites (PU/MXene-s-BHET) with functional crosslinked network structure were prepared via bio-based polyol BHET modified bio-based hydrogenated dimer acid (PBHDA) and functionalied MXene (MXene-s-BHET). MXene-s-BHET was fabricated through 3-isocyanatopropyltriethoxysilane (IPTS) as a surface modifier between BHET and MXene by covalent bonds and hydrogen bonds, thereby enabling crosslinking effect. MXene-s-BHET can not only form crosslinked network structure with the PU chains to enhance the interfacial bonding between filler and PU, but also promote the fine dispersion for the filler in matrix on endow composites with remarkable mechanical performance and functionality. Only containing 2 wt% MXene-s-BHET endows PU/MXene-s-BHET2 with a high electrical conductivity of 9.65 × 10<sup>−3</sup> S/m, thermal conductivity of 0.687 W m<sup>−1</sup> K<sup>−1</sup> (increased by 271.4 %), and electromagnetic interference shielding efficiency of 26.8 dB in the X-band. Furthermore, the PU/MXene-s-BHET2 composites exhibit excellent mechanical properties (elongation at break of 472.3 % and tensile strength of 20.1 MPa), storage modulus and heat resistance. Hence, this work will open new path for promoting the high-value recycling of resources and the innovation for functional polyurethanes.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102598"},"PeriodicalIF":7.7,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262730","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Recent progress on composite hydrogels and their integrated devices for atmospheric water harvesting","authors":"Xujiao Wu , Junyi He , Zijin Lao, Xiaohan Ning, Jintao Zhu, Lianbin Zhang","doi":"10.1016/j.coco.2025.102601","DOIUrl":"10.1016/j.coco.2025.102601","url":null,"abstract":"<div><div>The global shortage of freshwater resources has become a pressing issue, driving the development of alternative technologies for freshwater production. One promising solution is atmospheric water harvesting (AWH) technology, which focuses on extracting water vapor from the air. Hydrogels, with their three-dimensional network structure, high swelling rate, excellent hydrophilicity, and fast adsorption/desorption dynamics, are emerging as essential materials for AWH. By incorporating hygroscopic or photothermal components, composite hydrogels can significantly enhance atmospheric moisture capture and facilitate water release. This review article provides a recent progress of the synthesis methods, various structures, and functionalities of composite hydrogels in the context of AWH. We discuss the moisture absorption properties of different composite hydrogel types and their performance in AWH. Additionally, diverse AWH devices based on composite hydrogels, which are designed to maximize water collection efficiency, have been introduced. Finally, we provide insightful perspectives on the potential advancements and future directions in this rapidly growing field of composite hydrogels for AWH.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102601"},"PeriodicalIF":7.7,"publicationDate":"2025-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145226936","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xueying Wang , Can Wu , Maoyong Zhi , Jiaxin Zheng , Sicheng Liu , Xiangyu Jin , Changqing Hong
{"title":"In-situ constructuring boron-modified phenolic aerogels with enhanced mechanical performance and flame retardancy","authors":"Xueying Wang , Can Wu , Maoyong Zhi , Jiaxin Zheng , Sicheng Liu , Xiangyu Jin , Changqing Hong","doi":"10.1016/j.coco.2025.102596","DOIUrl":"10.1016/j.coco.2025.102596","url":null,"abstract":"<div><div>Phenolic aerogels are widely used in aerospace applications owing to their inherent flame retardancy, which exceeds that of combustible organic aerogels. However, these materials remain susceptible to smoldering even after being removed from an open flame, due to oxygen diffusion through their porous carbon structure, sustaining internal exothermic reactions. To mitigate the effects of their smoldering combustion, this study focuses on boron modification of the surface of phenolic aerogels’s porous framework. The results show that the material's limiting oxygen index (LOI) increased from 26.9 % to 29.9 %, while its peak heat release rate (pkHRR) decreased by 20.07 % in cone calorimetry tests. Moreover, total smoke production (TSP) dropped by 69.72 %, demonstrating significantly improved flame retardant properties. The materials demonstrated excellent mechanical properties, with tensile, flexural, and compressive strengths of 14.70 MPa, 23.49 MPa, and 7.15 MPa, respectively. This study presents a novel approach to developing phenolic aerogel composites that combine high flame retardancy, superior mechanical performance, and effective thermal insulation, showing great potential for building fire protection and aerospace applications.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102596"},"PeriodicalIF":7.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145226853","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Xiaonan Lu , Jianchao Li , Tianzi Wang , Cheng Liu , Wenting Ouyang , Bowen Gong , Sainan Ma , Likun Wang , Huan Wang , Bo Yuan , Zhong Zheng , Xiang Gao , Hua-Xin Peng
{"title":"Tuning biomimetic open-cell foam structure: a promising way to tailor the mechanical behaviors of two-phase composite","authors":"Xiaonan Lu , Jianchao Li , Tianzi Wang , Cheng Liu , Wenting Ouyang , Bowen Gong , Sainan Ma , Likun Wang , Huan Wang , Bo Yuan , Zhong Zheng , Xiang Gao , Hua-Xin Peng","doi":"10.1016/j.coco.2025.102599","DOIUrl":"10.1016/j.coco.2025.102599","url":null,"abstract":"<div><div>Natural organisms have evolved diverse porous/foam architectures for optimal performance of two-phase composite. Inspired by these biological designs, this work develops a novel Voronoi-based modelling method for open-cell foams. The method regulates scaffold morphology through single geometry parameter, i.e. intercellular distance <em>d</em>, generating biomimetic geometries ranging from pomelo-peel-like to trabecular-bone-like structures. Using SiC<sub>3D</sub>/Al composites as model materials, the geometry-property relationship is established by finite element analysis (FEA). For these foam-reinforced composites, larger SiC/Al interfaces enhance load transfer efficiency. Consequently, strength decreases monotonically (356 → 326 MPa) with increasing <em>d</em> due to reduced interface area. Extreme <em>d</em> values (low or high) cause sharp and concave features that trigger catastrophic SiC<sub>3D</sub> fragmentation, reducing ductility. Peak elongation (3.98 %) occurs at <em>d</em> = 0.65. Thus, optimal performance requires <em>d</em> ≤ 0.65. Structural design alone cannot simultaneously maximize strength and toughness. The matrix-reinforcement compatibility is essential, demanding tough matrices and ultra-strong reinforcements.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102599"},"PeriodicalIF":7.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145154609","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yi Su , Qingsong Ma , Junping Li , Xiaozhou Wang , Xiaokuo Guo , Sian Chen
{"title":"Ultrahigh-temperature stability and SiC decomposition behaviour in HfC-SiC ceramics derived from non-oxygen precursor","authors":"Yi Su , Qingsong Ma , Junping Li , Xiaozhou Wang , Xiaokuo Guo , Sian Chen","doi":"10.1016/j.coco.2025.102600","DOIUrl":"10.1016/j.coco.2025.102600","url":null,"abstract":"<div><div>HfC-SiC ceramics are promising for ultrahigh-temperature applications, yet their structural degradation due to SiC decomposition at 2500 °C remains underexplored. In this study, HfC-SiC nanocomposites with a uniform nanoscale microstructure were successfully fabricated via the polymer-derived ceramics route using a liquid, non-oxygen PHNCS precursor. Upon heat treatment at 2500 °C, significant SiC decomposition occurs, and the volatilization of silicon promotes the deposition of residual carbon as graphitic layers on HfC particles, forming a HfC@C structure. Commercial SiC exhibits much less decomposition than the HfC-SiC nanocomposites. This may be attributed to nano-sized HfC particles that precipitate on the SiC surface above 1900 °C, which act as defects and accelerate SiC decomposition at extreme temperatures. These findings elucidate the structural degradation mechanisms of HfC-SiC ceramics at ultrahigh temperatures and provide valuable insights for defining their upper service temperature and guiding the design of optimized multiphase architectures.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102600"},"PeriodicalIF":7.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262731","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}