Composites Part A: Applied Science and Manufacturing最新文献

{"title":"Recycling flax fibre composites by using a chemical solvolysis process in near- and supercritical conditions: linking fibre integrity to micro-mechanical performance","authors":"Coralie Buffet ,&nbsp;Jing Wang ,&nbsp;Sylvie Durand ,&nbsp;Anthony Magueresse ,&nbsp;Cyril Aymonier ,&nbsp;Alain Bourmaud","doi":"10.1016/j.compositesa.2026.109595","DOIUrl":"10.1016/j.compositesa.2026.109595","url":null,"abstract":"<div><div>The growing demand for bio-based composites has intensified the need for efficient recycling strategies that preserve fibre integrity and reduce environmental impact. In this study, unidirectional flax-reinforced composites with epoxy and poly-amide 11 (PA 11) matrices are manufactured and subsequently recycled using a solvolysis-recycling based process under near- and supercritical conditions in a semi-continuous flow reactor. A water/ethanol mixture (50/50 in mol) is employed as solvent at 250°C and 300°C under 250 bar. The recovered flax fibres are characterised using scanning electron microscopy (SEM), nanoindentation (NI) and atomic force microscopy (AFM). Mechanical tests on the original composites demonstrate tensile properties consistent with the best values reported in the literature, supported by low porosity levels (∼2%). After solvolysis, flax fibres recovered from PA 11 composites exhibit clean surfaces, preserved cell wall organisation, and nano-mechanical properties close to virgin fibres. In contrast, fibres from epoxy composites experience substantial degradation, especially at 300°C, with pronounced ultrastructural damage and a 65.8% reduction in indentation modulus. AFM confirms localised degradation patterns and lumen-driven damage pathways. These results highlight the superior recyclability of Flax – PA 11 systems and the intrinsic limitations of Flax – Epoxy composites for fibre-preserving solvolysis. Overall, the study provides composite manufacturers and recyclers with new insights into fibre-scale degradation mechanisms and supports the development of more circular, eco-efficient bio-composite architectures.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"203 ","pages":"Article 109595"},"PeriodicalIF":8.1,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035093","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":"Physicochemical and biological evaluation of Bioinspired Zea mays starch-derived self-healing composite hydrogels with dynamic boronate crosslinks for critical bone defects","authors":"Aqsa Afzaal ,&nbsp;Mazhar Amjad Gilani ,&nbsp;Catherine Petit ,&nbsp;Olivier Huck ,&nbsp;Sobia Tabassum","doi":"10.1016/j.compositesa.2026.109573","DOIUrl":"10.1016/j.compositesa.2026.109573","url":null,"abstract":"<div><div>Bioinspired self-healing hydrogels were developed as a minimally invasive, bioactive platform to overcome the inherent limitations of conventional bone scaffolds, using Zea mays starch (ZS), poly(vinyl alcohol) (PVA), and hydroxyapatite (HA), crosslinked through dynamic boronate ester bonds. The ZS-series hydrogels exhibited remarkable shape adaptability, syringe extrudability, and rapid self-healing within 3–5 s. FTIR supported boronate complexation, while XRD indicated retained HA crystallinity. Improved thermal stability and moderate wettability (contact angle 66–75°) supported cell adhesion. Rheological analyses revealed G′ &gt; G″ with excellent thixotropic recovery, ensuring mechanical integrity and extrudability under conditions relevant to minimally invasive delivery. The hydrogels exhibited shear-thinning behavior and ionic conductivity, highlighting potential for bioelectrical stimulation during tissue repair. Among formulations, ZS1.4 displayed optimal recovery after high-strain disruption and balanced physicochemical performance. Hemolysis ratios below 5 %, suppressed TNF-α (p &lt; 0.0001), and fibroblast and epithelial cells viability comparable to controls confirmed biocompatibility. <em>In vitro</em> scratch assays showed accelerated wound closure, and <em>in vivo</em> critical calvarial defect studies demonstrated substantial osteogenic and new bone formation without adverse effects. Overall, ZS1.4 presented the best combination of structural stability, bioactivity, and regenerative potential, by integrating high HA loading with rapid network reversibility, establishing it as a multifunctional, self-healing scaffold for minimally invasive bone tissue engineering.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"203 ","pages":"Article 109573"},"PeriodicalIF":8.1,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035205","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":"Synergistic enhancement of heat resistance and mechanical performance of epoxy resin by introducing entanglement effect","authors":"Zimin Luo ,&nbsp;Liming Wang ,&nbsp;Bin Cao ,&nbsp;Yuhao Liu ,&nbsp;Xiaobang Tong ,&nbsp;Libao Liu ,&nbsp;Xiaoqing Wu ,&nbsp;Xukai Zhu","doi":"10.1016/j.compositesa.2026.109581","DOIUrl":"10.1016/j.compositesa.2026.109581","url":null,"abstract":"<div><div>The inherent molecular structure of epoxy composites make it difficult to synergistically enhance their heat resistance and mechanical performance. Precise molecular structure design provides an effective approach to solving this problem. By introducing entanglement structures into epoxy composites, this study successfully addresses this trade-off issue. Small-angle X-ray scattering (SAXS) and X-ray diffraction (XRD) confirm the entanglement network induced by the long carbon chain molecular structure in the epoxy composites. The inclusion of rigid benzene rings facilitates the synergistic improvement of thermal stability and mechanical performance in epoxy composites. Compared with pure epoxy resin (EP), the glass transition temperature, tensile strength, elongation at break, and impact strength of modified epoxy resin (EP-BTDA-10) are increased by 9.00%, 21.70%, 14.50%, and 24.97%, respectively. The constraints on molecular motion from entanglement at high temperatures, coupled with long carbon chains, result in increases of 109.48% in tensile strength and 211.62% in elongation at break for EP-BTDA-10 at 90°C. The entanglement network enhances the cross-linking density of epoxy composites, leading to an 11.84% increase in alternating current breakdown field strength and an order-of-magnitude improvement in resistivity. This study provides a new insight for the design of high heat resistance and high toughness insulating materials with customizable designs for electrical applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"203 ","pages":"Article 109581"},"PeriodicalIF":8.1,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974268","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":"Ablation-resistant shape memory polyimide composite aerogels with exceptional high temperature response for smart thermal protection","authors":"Zhaoyang Tang,&nbsp;Xu Zhang,&nbsp;Leihao Su,&nbsp;Pengjie You,&nbsp;Xuan Li,&nbsp;Wei Fan,&nbsp;Tianxi Liu","doi":"10.1016/j.compositesa.2026.109570","DOIUrl":"10.1016/j.compositesa.2026.109570","url":null,"abstract":"<div><div>Shape memory polyimide aerogel (SMPIA), a novel class of intelligent deformable material, has attracted significant attention in aerospace and advanced engineering fields due to its unique combination of low density, porous structure, and exceptional thermostability under extreme conditions. However, the SMPIA has certain defects such as severe volume shrinkage during the moulding process, slow recovery, and irreversible shape change at extreme temperatures (e.g., under direct flame exposure). The alumina (Al₂O₃) is often used to optimize material properties due to its excellent thermal stability and mechanical properties. In this work, the shape memory polyimide composite aerogels (SMPICAs) were prepared by incorporating the Al₂O₃ ceramic particles as the reinforcing phases to effectively solve the significant volume shrinkage during the preparation process, and the SMPICAs exhibit favourable thermal insulation and ablation resistance. Under high-temperature testing, the SMPICAs demonstrated the great shape memory performance and cycling stability over multiple cycles. In the fifth shape memory cycle, both the shape fixation and recovery ratio exceeded 97 %. The SMPICAs can complete shape recovery when exposed to the flame within 8 s and almost maintain the original shape, which displays important application potential in the fields of aerospace and intelligent thermal protection systems, etc.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"203 ","pages":"Article 109570"},"PeriodicalIF":8.1,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974279","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":"Evaluation of nanodiamond and short glass fiber-reinforced dental composites: Mechanical, optical, and biological characterization","authors":"Negar Mahmoudi Meimand ,&nbsp;Junjing Zhang ,&nbsp;Lamia Singer ,&nbsp;Honghao Gong ,&nbsp;Minji Kwon ,&nbsp;Michael Francis Burrow ,&nbsp;Zhiqin Chu ,&nbsp;James Kit Hon Tsoi ,&nbsp;Kiho Cho","doi":"10.1016/j.compositesa.2025.109540","DOIUrl":"10.1016/j.compositesa.2025.109540","url":null,"abstract":"<div><div>Despite advancements in dental resin composites, issues such as bulk fracture and recurrent caries continue to hinder their performance and durability. This study evaluates a novel composite incorporating nanodiamonds and short S-glass fibers, aimed at enhancing mechanical and antibacterial properties while maintaining aesthetics. Four composite groups were prepared: ND-Sgf (50 wt% resin, 10 wt% S-glass fibers, 40 wt% glass particles, 0.2 wt% nanodiamonds, 1.0 wt% photoinitiators), ND (without S-glass fibers), Sgf (without nanodiamonds), and a control (without nanodiamonds or fibers). Key properties, including degree of conversion, flexural strength (FS), flexural modulus (FM), surface roughness, hardness, shade, transparency, and antibacterial activity against <em>Streptococcus mutans</em> were analyzed by one-way analysis of variance, followed by multiple comparisons (SPSS software (α = 0.05))The ND-Sgf group exhibited significantly higher flexural modulus (7.27 ± 0.33 GPa) and Vickers hardness (32.66 ± 0.99 VH) than their respective controls. Additionally, after 24 h, ND-Sgf showed significantly lower <em>S. mutans</em> adhesion (122 ± 46.92 × 10⁴ CFU/ml) compared to the Sgf group (386.6 ± 115.16 × 10⁴ CFU/ml, <em>p</em> = 0.013), with cell viability comparable to controls (<em>p</em> &gt; 0.05). The BPA-free dental resin composites reinforced by surface-modified glass fibers and nanodiamonds demonstrated marked improvements in mechanical, antibacterial, and aesthetic properties, indicating promising potential for advanced dental restorative applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109540"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836496","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":"High-temperature mechanical performance and fire retardancy of polysilazane/epoxy-based basalt fiber reinforced polymer laminates","authors":"Jianxun Liu ,&nbsp;Hirwa Nshuti Roger ,&nbsp;Xingchen Li ,&nbsp;Zhengjie Zhu ,&nbsp;Husam A.R. Husam ,&nbsp;Yuxin Zhou ,&nbsp;Zhishen Wu","doi":"10.1016/j.compositesa.2025.109536","DOIUrl":"10.1016/j.compositesa.2025.109536","url":null,"abstract":"<div><div>Epoxy resin’s adhesion and mechanical properties make it the preferred FRP matrix, but its poor flame retardancy and thermal stability limit its use in fire-critical applications. present work integrated polysilazane (PSZ) into epoxy resin matrices to fabricate basalt fiber reinforced polymer (BFRP) laminates aimed at enhancing high-temperature mechanical stability and flame retardancy. Laminates with varying PSZ/epoxy ratios were produced. Comprehensive characterization included uniaxial tensile testing before and after temperature exposure, thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), Fourier transform infrared Spectroscopy (FTIR), vertical-burn, cone calorimetry, scanning electron microscopy (SEM), and post-fire low-velocity impact (LVI) testing. The 1:1 PSZ/epoxy(B-50EP50P) retained 115.7 % and 76.7 % of its original tensile strength after exposure to 200 ℃ and 400 ℃, respectively, outperforming neat epoxy (B-100EP). TGA demonstrated that PSZ-rich laminates maintained ≥ 90 % mass at 500 ℃. DMA revealed that storage modulus increases above 200 ℃ for PSZ-contained composites, indicating the in situ formation of a ceramic-like network. FTIR confirmed PSZ-containing laminates maintained spectral integrity after thermal exposure due to partial ceramization, while the neat epoxy laminate exhibited significant bond degradation. Vertical burn tests achieved self-extinguishment in under 10 s for pure PSZ (B-100P) and 15 s for B-50EP50P, with minimal char length. SEM confirmed the formation of a cohesive, ceramic-like char that protects the underlying fibers after surface burning. Post-fire LVI demonstrated that B-50EP50P exhibited elastic rebound at 10 J and a full-penetration threshold of 20 J, outperforming neat epoxy. PSZ/epoxy-based modified BFRP composites show promise for high-temperature fire retardancy applications<strong>.</strong></div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109536"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836582","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":"Microstructures, dynamics, and tensile properties of water-saturated epoxy nanocomposite enhanced by graphene and functionalized graphene","authors":"Jialin Liu ,&nbsp;Ning Hu ,&nbsp;Fenghua Nie ,&nbsp;Lik-ho Tam ,&nbsp;Xin Wang ,&nbsp;Zhishen Wu ,&nbsp;Denvid Lau","doi":"10.1016/j.compositesa.2025.109508","DOIUrl":"10.1016/j.compositesa.2025.109508","url":null,"abstract":"<div><div>Epoxy composites are valued in wind turbine blades for their lightweight and fatigue-resistant characteristics. The epoxy composites suffer from moisture-induced mechanical degradation. The water penetration and hydrothermal effects weaken the material properties. To address the mechanical degradation, graphene and functionalized graphene are incorporated to hinder the movement of water molecules and epoxy chains. The presence of these nanosheets reduces the epoxy’s free volume from approximately 43 % to 36 %. At 350 K, the tensile modulus is increased from 2.7 ± 0.4 GPa in pure epoxy to 3.0 ± 0.6 GPa in epoxy with hydroxyl-functionalized, 3.4 ± 0.7 GPa in epoxy with amine-functionalized graphene, and 3.4 ± 0.6 GPa in epoxy with carboxyl-functionalized graphene. Concurrently, water diffusion coefficients is decreased significantly from (5.55 ± 0.21) × 10⁻¹¹ m2/s in pure epoxy to (3.04 ± 0.27) × 10⁻¹¹, (2.19 ± 0.17) × 10⁻¹¹, and (2.11 ± 0.15) × 10⁻¹¹ m2/s in the respective functionalized nanocomposites. The contributions of different functional groups to the microstructure, water diffusion, and mechanical properties highlight the potential of tailored graphene additives to enhance epoxy composites for blades, which give insights into the improvement and tunability in the hydrothermal resistance of epoxy nanocomposites by adopting appropriate groups on graphene and epoxy chains, and mitigate moisture-induced degradation and damage while improving durability.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109508"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145797397","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":"High-thermal-conductivity submicron pores graphene phase change composites for rapid solar energy harvesting in Antarctic","authors":"Rui Zhang ,&nbsp;Xianxian Sun ,&nbsp;Shasha Wang ,&nbsp;Peijia Bai ,&nbsp;Ruichuan Li ,&nbsp;Yu Ma ,&nbsp;Yibin Li","doi":"10.1016/j.compositesa.2025.109480","DOIUrl":"10.1016/j.compositesa.2025.109480","url":null,"abstract":"<div><div>Solar energy has emerged as nearly the sole viable renewable energy source for Antarctic expeditions, yet its application is constrained by limited daylight hours. Thus, leveraging phase change materials (PCMs) to rapidly convert and store solar energy as heat is pivotal to addressing the energy challenge. However, traditional PCMs, suffer from low thermal conductivity and sluggish heat storage, restricting heat accumulation within the available light period. In this study, PCM performance was improved via the incorporation of sub-micron high-thermal-conductivity graphene foam. Highly aligned graphene foam (GAGF) was fabricated using high-velocity radial gas jets combined with axial compression from Polymethyl methacrylate (PMMA)-expanded microspheres. It exhibits an exceptional orientation degree (0.32) and a thermal conductivity of 25.29 W/(m·K) a 93 % enhancement over non-airflow-oriented graphitized graphene foam (GGF). Post-PCM infiltration, this value further rises to 43.91 W/(m·K). Benefiting from high orientation and submicron pores (0.03–100.44 μm), GAGF phase change composites (PCCs) shorten heat transfer paths, accelerating phase transition and reducing response time. Under 1000 W/m² solar irradiation, the 4 × 3 × 0.5 cm³ GAGF PCCs achieved a volumetric thermal energy storage rate of 12.99 J/(min·cm³), a 126 % increase versus pure PCM. This research provides significant implications for efficient solar energy storage in Antarctica.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109480"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145797399","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":"Multiscale toughening-driven lattice-structured titanium matrix composites: Breakthrough in strength-toughness synergy","authors":"Jinguang Li ,&nbsp;Mi Zhou ,&nbsp;Jieren Yang ,&nbsp;Yisheng Mou ,&nbsp;Jian Wang ,&nbsp;Shidong Zhu ,&nbsp;Hui Zhao ,&nbsp;Han Zhao","doi":"10.1016/j.compositesa.2025.109463","DOIUrl":"10.1016/j.compositesa.2025.109463","url":null,"abstract":"<div><div>Titanium matrix composite (TMC) drill rods possess significant potential for application in ultra-deep wells at depths of tens of kilometers. However, the traditional composite design is difficult to break through the inherent “strength-plasticity/toughness” inversion contradiction of titanium alloy. This study proposes a novel multi-scale design strategy for Weair-Phelan lattice structure toughened titanium matrix composite (WP-TMC), successfully achieving tensile strength &gt; 1200 MPa, elongation &gt; 10 %, and fracture toughness K_ⅠC &gt; 75 MPa m^−1/2, which has a superior strength-ductility-toughness matching far surpassing that of other TMCs. Fine equiaxed α grains and dispersed in situ TiB particles in WP lattice structure was obtained by selective laser melting (SLM) process, meanwhile the Widmanstätten structure in matrix was controlled by hot-pressing process, where the interfacial reaction was inhibited and the strong metallurgical interface was successfully obtained. The multi-scale interfaces are the key to induce dislocation strengthening and Hall-Petch strengthening as well as interface toughening by interacting with cracks. The cross-scale coupling of “dislocation-interface” and “interface-crack” make WP-TMCs overcome the limitations imposed by the classical mechanical property mixing rules governing traditional titanium alloys and their composites. This work can provide both theoretical support and practical guidance for the design of a new generation of TMCs.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109463"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623339","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":"Integrating additively manufactured continuous glass fibre inserts in compression moulding: A novel approach to mitigating fibre–matrix separation effect","authors":"Udane Olaziregi,&nbsp;Aritz Esnaola,&nbsp;Maider Baskaran,&nbsp;Jon Aurrekoetxea","doi":"10.1016/j.compositesa.2025.109497","DOIUrl":"10.1016/j.compositesa.2025.109497","url":null,"abstract":"<div><div>This study presents a novel approach to mitigate fibre–matrix separation defects in compression-moulded thermoplastic composite components by integrating additively manufactured (3D-printed) continuous fibre-reinforced inserts into the stiffener ribs. The design of these inserts was guided by topology optimisation and refined to align with additive manufacturing principles. The feasibility of embedding 3D-printed inserts was demonstrated, yielding hybrid parts with consistent quality, accurate positioning, and a defect-free insert/moulded part interface. Mechanical testing under three-point bending revealed substantial performance gains: stiffness, strength, deflection, and energy absorption improved by factors of up to 1.5, 3.5, 1.4, and 12, respectively. A 45 % reduction in insert thickness further enhanced manufacturability and interfacial bonding, shifting the failure mode from interfacial delamination at the rib base to fibre rupture at the rib tip. Despite the reduced material volume, stiffness decreased by only ∼17 %, while strength remained stable and toughness improved significantly.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"202 ","pages":"Article 109497"},"PeriodicalIF":8.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748321","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}