Rourkela: Researchers at the National Institute of Technology-Rourkela (NIT-R) have secured a patent for a novel 3D-reinforced composite manufacturing technology that enhances the strength and durability of fibre-reinforced polymer (FRP) composites used in aerospace, automotive and renewable energy applications.The patented technology, developed by the FRP Composite Lab of NIT-R’s department of metallurgical and materials engineering, offers a solution to one of the key limitations of conventional FRP composites: their vulnerability to damage under high stress, which can lead to cracking, delamination and reduced performance.According to a press release issued by the institute on Friday, the research was carried out by Dr Rajesh Kumar Prusty, assistant professor, Prof Bankim Chandra Ray, professor, and research scholar Parimal Jana of NIT-R, in collaboration with Dr Dinesh Kumar Rathore of MNIT Jaipur’s department of mechanical engineering.FRP composites are used in commercial aircraft, defence platforms, space launch vehicles, high-speed rail systems, renewable energy infrastructure and hydrogen storage tanks because of their high strength-to-weight ratio, corrosion resistance and design flexibility. However, their performance can deteriorate when subjected to prolonged or heavy mechanical loads.The researchers developed a hybrid three-dimensional reinforced composite that integrates glass fibres with graphene nanoplatelets aligned through the thickness of the material during manufacturing. It creates a stronger internal structure, enabling the fibres, graphene and epoxy matrix to work together more effectively and produce a damage-resistant composite.A key feature of the technology is a simple manufacturing process that aligns unmodified graphene nanoplatelets within glass fibre-reinforced epoxy composites. The researchers achieved this by applying a standard 50 Hz alternating current electric field at 800 volts during the curing stage, with only minor modifications to existing manufacturing methods.“Our technology has wide-ranging applications in sectors where lightweight yet damage-tolerant materials are required. Aircraft panels, automotive crash structures, wind turbine blades, pressure vessels, marine structures and other advanced engineering components are some of the areas where the innovation can be directly deployed,” said Prusty.Laboratory tests conducted as per ASTM standards showed substantial improvements in material performance, including a 37% increase in tensile strength, 30% higher flexural strength, 63% improvement in flexural modulus, 24% increase in tensile modulus, 24% improvement in interlaminar shear strength, 33% rise in Mode-I fracture toughness, 53% increase in Mode-II fracture toughness and 55% higher storage modulus at 40°C.Ray said the innovation could help lower maintenance costs, improve energy efficiency and promote sustainable manufacturing practices. “By improving durability while reducing weight, the technology has the potential to contribute to India’s Atmanirbhar Bharat mission in advanced materials,” he said. The research team plans to test the material in larger structural components and assess its long-term environmental durability. Efforts are underway to pursue technology licensing and industry partnerships to facilitate commercial deployment of the innovation.
