Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com slide Multifunctional Composites: Technical Overview and Market Analysis Dr Richard Collins, Senior Technology Analyst
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com slide
Multifunctional Composites: Technical
Overview and Market Analysis
Dr Richard Collins, Senior Technology Analyst
Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com slide
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Advanced Materials Research
For full details and list of available reports visit www.IDTechEx.com
Additive Manufacturing and
Lightweight Materials for
Aerospace & Defense 2018-2028www.IDTechex.com/lightaero
Composites 2017-2027:
Innovations, Opportunities, Market
Forecastswww.IDTechex.com/composites
Graphene, 2D Materials & Carbon
Nanotubes: Markets, Technologies &
Opportunities 2018-2028www.IDTechex.com/Graphene
Conductive Ink Markets 2018-
2028: Forecasts,
Technologies, Playerswww.IDTechex.com/ink
Lightweight Metals 2018-
2028: Forecasts,
Developments, Playerswww.IDTechex.com/lightweightmetals
Barrier Layers for Flexible
Electronics 2017-2027:
Technologies, Markets, Forecastswww.IDTechex.com/barrier
Electrically Conductive
Adhesives 2016-2026www.IDTechex.com/adhesives
Aerogels 2017-2027: Technologies,
Markets and Playerswww.IDTechex.com/aerogel
Functional Materials for Future
Electronics: Metals, Inorganic & Organic
Compounds, Graphene, CNTwww.IDTechex.com/materials
Non-Toxic Materials & Alternatives
in Electronics/Electrics: Large
Emerging Markets 2018-2028www.IDTechex.com/Toxic
Perovskite Photovoltaics
2018-2028www.IDTechex.com/perov
Quantum Dots 2016-2026:
Applications, Markets,
Manufacturerswww.IDTechex.com/qd
Structural Electronics
2018-2028: Applications,
Technologies, Forecastswww.IDTechex.com/structural
Supercapacitor Materials
and Technology Roadmap
2019-2039www.IDTechex.com/scmats
Transparent Conductive Films and
Materials 2018-2028: Forecasts,
Technologies, Playerswww.IDTechex.com/tcf
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IDTechEx at Advanced Engineering 2018
Day OneThe Rapidly Evolving Market for
Autonomous VehiclesDAY 1 (31ST OCTOBER) 13:00 | AUTOMOTIVE ENGINEERING FORUM
Presented By: Aman Atak, Technology Analyst
Additive Manufacturing in Aerospace &
Defence: Facts & Forecast DAY 1 (31ST OCTOBER) 15:00 | AERO ENGINEERING FORUM
Presented By: Dr Bryony Core, Technology Analyst
5G Enable The Industrial IoT:
Market Evaluation & ImplementationDAY 1 (31ST OCTOBER) 15:30 | CONNECTED MANUFACTURING FORUM
Presented By: Dr Luyun Jiang, Technology Analyst
Electric Vehicles:
The Melodrama of the coming 20 yearsDAY 2 (1ST NOVEMBER) 11:45 | AUTOMOTIVE ENGINEERING FORUM
Presented By: Franco Gonzalez, Principal Analyst
Multifunctional Composites:
Technical Overview & Market AnalysisDAY 2 (1ST NOVEMBER) 12:00 | ADVANCED MATERIAL FORUM
Presented By: Dr Richard Collins, Senior Technology Analyst
Tethered Drones Generating kW-MW:
Airborne Wind EnergyDAY 2 (1ST NOVEMBER) 14:45 | AERO ENGINEERING FORUM
Presented By: Dr Peter Harrop, Chairman
Day Two
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For full details and list of available reports visit www.IDTechEx.com
IDTechEx.com/multi
Presentation Overview:
Progressing away from “dumb” structural materials
is being observed in many sectors.
Composites have a great opportunity given their
beneficial properties and status in high-performance
industries.
There are numerous different functions being
explored at different stages of technology
readiness.
Global market drivers in connectivity, electrification,
automation, and lightweighting are all excellent pull-
factors.
IDTechEx have produced the first comprehensive
report dedicated to this field based on primary
research – contact us for more info.
Multifunctional Composites 2019-2029
7
Multifunctional Composites 2019-2029
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1 2 3 4 5 6 7 8 9
Thermal and Electrical Conductivity
Embedded Sensors
Data and Power Transmission
Adaptive Response (or Morphing)
with embedded actuators
Energy harvesting and energy storage
Self-healing
Technology Readiness Level (TRL) of Multifunctional Polymer Composites
Introduction to multifunctional polymer composites
Multifunctional Composites 2019-2029
Fully embedded circuitry
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What is structural electronics?
Rapid customization, material & component cost reduction, light-weighting and saving space are key drivers
Structures become functional components
3D Surface
Printing
In-Mold
Electronics
“Components in a Box”
1900
Pre
sen
t
Structural Electronics
Smart Skins
Load-bearing Components
Energy
Harvesting skin
Source: UW-MadisonSource: Volvo
Load-Bearing
Supercap
Source: Testo
Surface
Electronics
Multifunctional Composites 2019-2029
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Multifunctional Composites 2019-2029
Semi Commercial TrialsProof of Concept Early Semi-Commercial
Prototype
Active Adaptation for UAVs
Early Commercial
SalesFull Market Launch Market Penetration Maturity
Passive Adaptation Conductive
Sensors
Energy Storage
and Harvesting
Adaptive Response
Key
Status of multifunctional composites by application
FOS for Aerospace
Structural Batteries
Acousto-Ultrasonic Sensors
Structural
Supercapacitors
Data
Encased data
transmission
Embedded data transmission
initially UAVs Solar Skins
De-Icing Wind Turbines
De-Icing Aerospace
Embedded EMI shielding aerospace wings
Lightning Strike Protection aerospace
Integrated Li-ion battery
FOS for Oil & Gas and COPV
EMI shielding electronic housings
Active Adaptation for
turbines
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Routes to incorporating nanocarbon material into
composites
Included in resin
Including the additive in the resin before using in
prepreg or resin infusion
Relatively straightforward and minimal extra cost.
Versatile in terms of additive
Agglomeration can occur and difficult to monitor distribution.
Limited to low %. Can affect resin (eg viscosity)
CNT: OCSiAl, Arkema, Nanocyl, Cnano, Kumho…..
Graphene: Thomas Swan, Haydale, XGSciences, Standard Graphene….
Interlaminar veil or sheet
The nanocarbon is made into a sheet which is
stacked as part of laminate
Prevents delamination, included in lay-up process,
sheet means uniformity
Not fully integrated across part (properties more localised),
limited by veil depth and supply chain
General Nano, Tortech Nano Fiber, N12 Technologies
Fiber sizings
The nanocarbon acts as the coating to the fiber that
then interacts with the solvent
Good contact and dispersion into matrix.
Extra step to fiber processing, challenges in handling, limited to
low %, SP Nano, University of Surrey
Continuous yarn
The fiber itself is made of nanocarbon eg CNT yarn
The fiber itself has all the benefits the additives try to introduce. Good uniformity,
can be interwoven
Depending on yarn the performance inferior to individual additives, needs extra steps to
make larger/denser fibers
Nanocomp (Huntsman), DexMat, Muratec
Mixed with SMC
constituents
As the SMC is being made the nanocarbon is included
with other additives.
Relatively straight forward introduction, versatile for
additive.
SMC lower performing than continuous fibers, low %,
agglomeration can occur and difficult to monitor distribution.
University of Michigan (XGSciences),
Con
tin
uous fib
er
co
mp
osite
sS
ho
rt fib
er
co
mp
osite
s
Process Advantages Disadvantages Main Players
Multifunctional Composites 2019-2029
Complete analysis in the report:
Multifunctional Composites 2019-2029
11
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This can be either as an
expanded mesh or foil on
the surface or included in a
resin (epoxy) and included
as a top layer in the layup.
Metallization of polymer composites
Source: doi:10.3934/matersci.2016.1.260
If woven in then called
interwoven wire fabric
(IWWF). IWWF was
used for fuselage of 787
(Toray)
Multifunctional Composites 2019-2029
Most commonly nickel is
fiber coatings, but copper is
emerging. The two key
challenges are incorporation
to a polymer matrix and
keeping the veil or coating
thin (low density) enough to
not impact weight.
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Key drivers for electrical property enhancements
Lightning Strike Protection
• Composite airframes aerospace are not conductive and therefore require an additional copper mesh for damage protection against lightning
• If this was not required, weight and additional manufacturing steps can be removed.
EMI Shielding
• Wires, structures and other appliances have more background and targeted electromagnetic interference.
• Additives that reduce the amount of EM waves transmitted can be of great advantage. Military will be the primary drivers.
Electrostatic Coating
• For both complex and high-volume parts electrostatic coatings (most notably paints) can be applied in an electrostatic fashion, raising the conductivity.
Complete Circuitry
• Notable for other functionality, most notable sensors and actuators, electrical enhancements will be required either as part of these processes or to complete the circuit.
Source:, doi:10.1039/C7TC02394D, https://doi.org/10.1016/j.compositesa.2014.08.010, sharppaiting
Multifunctional Composites 2019-2029
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Technology adoption for electrostatic discharge of
composites
Proof of ConceptEarly Semi-
Commercial Trials
Early Commercial
Sales Full Market Launch Market penetration Maturity
Metal mesh and foil
Interwoven metal
fibers
Metal coated fibers
and fabrics
Metal resin additive
Nanocarbon
veil/sheet or yarn
Nanocarbon resin
additive or sizing
2019
10-years
20-years
Here are adoption rates for different kinds for electrostatic discharge methods.
Nanocarbon utilisation will see the greatest acceleration over the next 20-year period.
Multifunctional Composites 2019-2029
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Composite de-icing applications
Multifunctional Composites 2019-2029
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Main 4 players – technology providers
Source: Mark Kusaiha, Nordex, GKN
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Embedded sensors for structural health monitoring of
composites – types
Optical Sensors Electrical Resistance Sensors Piezoelectric Sensors
Comparative
Vacuum
Monitoring
Eddy Current
Sensor
TypesInterferometric
sensors
Grating-based
sensors (includes
FBG)
Distributed
sensors (includes
OTDR)
Metallic foils
and crack wires
Printed Sensor
(includes
piezoresistive)
Piezoelectric
wafer active
sensors
(PWAS)
Piezoelectric
fibers
Advantages
Very high
resolution and
wide tolerance
range
Easy to integrate for
full life cycle, high
sensitivity, good
durability immune
from EMI, highly
multiplexed
Whole fiber acts as
sensor giving
excellent range.
Mature
technology,
simple materials
Easy to embed,
cost effective,
flexible and
versatile, can
utilise
nanocarbon
Can be
integrated into
laminar or
retrofitted, good
range and
sensitivity
Flexible, good
mechanical
properties, can
act as actuator,
sensitive and
good range
Durable, simple,
design flexibility,
Versatile
installation,
sensitive
DisadvantagesSingle point
detection, not very
durable
High number sensors
required for large
range, higher scan
rates increase
complexity
Poor resolution and
limited accuracy
Often bulky/
structurally
parasitic, lower
resolution,
limited range,
hard to embed
Adhesive
challenges,
localised range
Lower
multiplexing
capabilities
Lower
multiplexing
capabilities,
Lower sensitivity
(just on/off),
specific
locations
Adversely
affected by
temp, vibration
and EMI
Technology
Readiness
Main Sensor
Players
Optics 11,
OpSens
Technica, Fibercore,
FBGS, Fiberguide,
OFS, micron-optics,
IFOS, Smart Fibres,
HBM…
Luna Innovations,
Neubrex
TechnologiesHBM
Quest
Integrated
Acellent
Technologies,
Metis Design
Smart Material
Structural
monitoring
systems
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Multifunctional Composites 2019-2029
Complete analysis in the report: Multifunctional Composites 2019-2029
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Embedded Sensor – Applications
Multifunctional Composites 2019-2029
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doi:10.1016/j.compositesa.2011.02.006
There are several application sectors exploring
the use of embedded sensors such as.
o Aerospace and Defense
o Oil & Gas
o Overwrapped pressure vessels
o Turbines
o Composite manufacturing monitoring.
Aerospace and Defense is the main sector and
are the predominant players in patent assignees
and technical advancements.
Inflexion point for uptake is expected in
2021/2022 by IDTechEx. Full forecast and
player analysis in the market report.
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Evolution of embedded energy storage
Current Status
• Advances going into battery chemistry.
• 50% of the weight can be attributed to the box.
Integrated Li-ion
• TRL 4-5
• The box/casing is also structural.
• Li-ion cells can be incorporated into composite laminar structures.
Composite ES
• TRL 1-2
• The structural composite part also acts as the energy storage device.
• Typically modified CF acts as the electrodes.
Multifunctional Composites 2019-2029
Source: IDTechEx photos, DARPA, Stanford University, Chalmers University and Imperial College London
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Data and power transmission for an increasingly connected
and electrified world
Surface waves: Waves transferred along an interface between two
dielectrics.
Main Player: TWI
TRL: 3-4
Fiber as cable: An electrically insulative coating around a
structural conductive fiber (e.g. CF). Or aligned nanomaterials.
Main Player: Chalmers University
TRL: 1-2
Embedded Transmitter: A standard composite part specifically designed to act as a casing for 5G
transmission
Main Player: Exel Composites
TRL: 7-9
Multifunctional Composites 2019-2029
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What is the end goal?
Integrated 2D-
laminar (thin-film
battery, strain
gauge, etc)
Component in a
composite stack
Functional additive:
sheet, or
fiber/fabric coating
Sensing or
actuating functional
fiber
Smart Layer added
to lay-upIn-mold electronics
Functional additive:
resin infusion
3D Printed
composites with
functional fibers
Structural battery or
supercapacitor
3D Printed
Electronics
Lo
ca
lise
dB
ulk
Electronic complexity
Multifunctional Composites 2019-2029
20
2D
3D
Much of the enhanced functionality can be achieved in localised laminar form, but there is scope for much
greater electronic complexity spreading across the whole part.
This image categorises some of the key technologies. This includes the introduction to in-mold electronics and
3D Printed electronics.
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IDTechEx.com/multi
Progressing away from “dumb” structural materials
is being observed in many sectors.
Composites have a great opportunity given their
beneficial properties and status in high-performance
industries.
There are numerous different functions being
explored at different stages of technology
readiness.
Global market drivers in connectivity, electrification,
automation, and lightweighting are all excellent pull-
factors.
IDTechEx have produced the first comprehensive
report dedicated to this field based on primary
research – contact us for more info.
Conclusions
21
Multifunctional Composites 2019-2029
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Dr Richard Collins
Senior Technology Analyst