1,000 times self-healing tech could extend aircraft life by centuries

Researchers at North Carolina State University have developed a novel self-healing composite material capable of repairing itself over 1,000 times, potentially extending the lifespan of critical infrastructure from decades to centuries. This innovation targets the longstanding issue of interlaminar delamination—a form of internal cracking that has limited the durability of fiber-reinforced polymer (FRP) composites used in aircraft, automobiles, wind turbines, and spacecraft. By integrating a 3D-printed thermoplastic healing agent and embedded carbon-based heater layers into conventional FRPs, the material becomes two to four times more resistant to delamination and can self-repair cracks when electrically heated, restoring its structural integrity. The composite was rigorously tested through 1,000 cycles of induced fractures followed by thermal healing over 40 days, demonstrating sustained fracture resistance well above that of unmodified composites. Although some gradual decline in healing efficiency occurs due to microscopic fiber wear and chemical changes, statistical modeling indicates the material remains structurally viable for centuries. This technology