Sustainable high-performance natural fiber composites with integrated strain sensing for aeronautics and automotive applications

Integrating sensing capabilities into structures made of sustainable materials presents significant opportunities for advanced applications. This study develops smart fibre-reinforced composites using sustainable palm leaf fibres (PLF) specifically designed for automotive interior applications such as dashboard panels, door trim, seat structures, and centre console components, as well as aeronautic cabin interiors including wall panels, overhead compartments, seat frames, and galley structures.

The developed composites demonstrate mechanical properties comparable to conventional fibre composites while offering integrated sensing capabilities for structural health monitoring of interior systems. Systematic investigation reveals that 10 wt.% PLF content provides optimal balance between mechanical performance and sensing functionality suitable for interior component requirements. This optimal performance is achieved through the enhanced mechanical properties and surface characteristics provided by PLF incorporation, where the palm leaf fibres promote polar interactions due to hydroxyl groups and other polar functionalities, resulting in improved hydrophilicity and intermediate surface characteristics that are critical for sensing applications. The resulting smart composite exhibits exceptional strain sensitivity with a gauge factor of approximately 27, enabling real-time monitoring. The developed bio-based composites offer significant cost advantages with 30–40 % reduced production costs compared to conventional fibre systems and demonstrate scalable manufacturing potential for mass production.

This work demonstrates the successful development of sustainable, eco-friendly materials with advanced sensing capabilities that show promise for automotive and aerospace applications, contributing to a greener and safer future.