Articles tagged with "carbon-fiber-composites"
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
materialsself-healing-materialscomposite-materialsfiber-reinforced-polymersaerospace-materials3D-printingcarbon-fiber-compositesYouTuber builds 'world's largest' blended-wing aircraft prototype
A US startup, Natilus, has partnered with popular YouTuber Ramy RC to build a flying prototype of the Horizon, a Blended Wing Body (BWB) passenger aircraft designed to revolutionize air travel. Unlike traditional tube-and-wing planes, the Horizon features a manta ray–like carbon-fiber blended wing design aimed at reducing fuel consumption by 30% and accommodating 200 passengers in a spacious cabin. Ramy RC, known for his large-scale remote-controlled jet models, documented the prototype’s construction, showcasing the use of advanced carbon fiber composites combined with wood and foam for a lightweight yet durable structure. The 24-foot wingspan prototype was built using CAD models and custom 3D-printed molds to ensure aerodynamic precision. With engine nacelles, wings, and landing gear integrated, the prototype is mechanically ready for its maiden flight, which will be the critical test of its real-world performance and stability. Natilus is pursuing FAA certification and aims for a commercial debut in the early
materialscarbon-fiber-compositesaerospace-engineeringblended-wing-bodyprototype-aircraftfuel-efficiency3D-printingNorth Korea shows new long-range nuke as Kim heads to meet Xi, Putin
North Korea publicly unveiled its new long-range nuclear missile, the Hwasong-20, as leader Kim Jong Un prepared to attend a military parade in China alongside Presidents Xi Jinping and Vladimir Putin. The missile features a newly developed solid-fuel engine generating a maximum thrust of 1,960 kilonewtons, intended for use in both the existing Hwasong-19 ICBM and the future Hwasong-20 system. This solid-fuel technology, developed using carbon-fiber composite materials, allows for quicker missile deployment compared to traditional liquid-fuel designs. Kim’s inspection of the missile research institute and a new automated missile production facility highlights North Korea’s efforts to modernize its defense industry and enhance its strategic missile capabilities. The announcement comes amid North Korea’s broader goal to strengthen its nuclear arsenal’s range, payload capacity, and survivability to evade U.S. and allied missile defenses. The Hwasong-18, unveiled last year, reportedly has a range exceeding 15,
energymaterialssolid-fuel-technologymissile-propulsioncarbon-fiber-compositesdefense-manufacturingautomated-productionUS Coast Guard Report on Titan Submersible Implosion Singles Out OceanGate CEO Stockton Rush
The US Coast Guard’s Marine Board of Investigation released a critical report on the 2023 Titan submersible implosion, placing primary responsibility on OceanGate CEO Stockton Rush for numerous technical and managerial failures. The report accuses Rush of repeatedly misrepresenting the Titan as indestructible and highlights significant discrepancies between OceanGate’s written safety protocols and actual practices. The investigation, chaired by Jason Neubauer, emphasized that Rush’s leadership style fostered a toxic workplace environment that discouraged employees from raising safety concerns. Notably, the Titan was not registered, inspected, or certified by any recognized authority, and Rush allegedly lied about the submersible’s specifications during his Coast Guard credential application. The report details multiple technical flaws with the Titan’s innovative carbon fiber hull, including a history of operational failures such as a titanium dome detaching in 2021 and exposure to freezing conditions that could degrade the composite material. It suggests the fatal implosion at approximately 3,000 meters depth was likely caused by either
materialscarbon-fiber-compositestitaniumsubmersible-technologysafety-protocolsmarine-engineeringstructural-integrityIndian drone developer Raphe mPhibr raises $100M - The Robot Report
Raphe mPhibr Pvt. Ltd., an Indian drone manufacturer based in Noida, recently raised $100 million in a Series B funding round led by General Catalyst, bringing its total equity funding to $145 million. Founded in 2017 by siblings Vikash Mishra (chairman) and Vivek Mishra (CEO), the company specializes in producing drones made from light carbon-fiber composites with high strength-to-weight ratios. Raphe mPhibr offers nine drone models with payload capacities ranging from 4.4 to 441 pounds (1.9 to 200 kg), capable of covering distances between 12 and 124 miles (19.3 to 200 km) and operating swarms of up to 100 drones. The company manufactures most components domestically, including batteries, flight controllers, and materials, and plans to produce radars and high-end cameras in-house within 18 months. With around 600 employees—150 focused on research and over 250 on production—
robotdronesUAVcarbon-fiber-compositesautopilot-systemsaerospace-manufacturingIndian-drone-industry156-foot-long solid rocket motor produces 4 million pounds of thrust
Northrop Grumman successfully conducted a full-scale static fire test of NASA’s Booster Obsolescence and Life Extension (BOLE) solid rocket motor, the world’s largest segmented solid rocket motor built for human spaceflight. The 156-foot-long, five-segment booster produced over 4 million pounds of thrust during a two-minute test, monitored by more than 700 data channels. This new booster features a composite carbon fiber case, updated propellant formulation, and advanced components, resulting in over 10 percent increased performance compared to the current five-segment Space Launch System (SLS) booster. The enhanced efficiency allows the booster to deliver an additional five metric tons of payload to lunar orbit, a critical capability for deep space missions. The BOLE booster development, initiated in 2017, aims to replace aging components no longer in production while aligning with commercial manufacturing standards and supporting a U.S.-based supply chain. Northrop Grumman leveraged its extensive experience from previous NASA programs, including
energyrocket-propulsionsolid-rocket-motorcomposite-materialsspace-launch-systemaerospace-engineeringcarbon-fiber-compositesNREL Publishes Method for Recycling All Components in Carbon Fiber Composites - CleanTechnica
The National Renewable Energy Laboratory (NREL) has developed a novel, scalable, and cost-effective method to recycle all components of carbon fiber composites (CFCs), materials widely used in high-value products like aircraft, bicycles, and automobiles. CFCs consist of carbon fibers embedded in epoxy-amine resins, which are strong, lightweight, and expensive, but difficult to recycle due to the chemically interlocked and complex nature of the resin. Traditional recycling methods have been limited by the inability to dissolve or break down these resins without degrading the valuable fibers or wasting the resin’s chemical components. NREL’s breakthrough involves using hot acetic acid—essentially vinegar—to cleave the key bonds in the epoxy resins, solubilizing the polymer networks while preserving the chemical building blocks for reuse. This method was optimized to handle diverse resin formulations from various industries and was shown to recover carbon fibers without compromising their strength. In a demonstration, recycled fibers extracted from a scrap mountain-bike frame were used to
materialscarbon-fiber-compositesrecycling-technologyepoxy-resinssustainable-materialsNRELcomposite-materials-recyclingChina firm debuts flying bike with 44.7 mph speed, 31-mile flight range
Chinese tech company Kuickwheel has introduced the Skyrider X6, a hybrid flying motorcycle that combines ground and aerial mobility. Unveiled at CES 2025, the three-wheeled vehicle operates in two modes: a “reverse trike” mode for ground travel with a top speed of 43.5 mph and a 124-mile range, and a flight mode using a 6-rotor electric system reaching speeds up to 44.7 mph with a maximum flight range of 31 miles on the larger 21 kWh battery variant. The bike supports automated takeoff, landing, and route planning, alongside manual joystick control, and features a lightweight design made from carbon fiber composites and aviation-grade aluminum. Safety is enhanced through redundant motors, control systems, a ballistic parachute, and backup flight control logic. The Skyrider X6 is priced around $69,000 and is available for pre-order on Chinese platforms like JD.com. It offers fast DC charging,
robotelectric-vehicleflying-bikebattery-technologycarbon-fiber-compositesautomated-flighthybrid-transportation