The demand for lighter, stronger and more sustainable materials is accelerating across industries. In sectors such as aerospace, automotive, renewable energy and construction, composite materials are seen as a key enabler of improved performance, fuel efficiency and reduced environmental impact.
However, their broader adoption faces significant challenges. Manufacturing processes must be scaled without compromising quality or increasing waste, while material designs must balance high mechanical and thermal performance with recyclability and cost-effectiveness.
The Structural Composites research unit aims to address these pressing challenges through the development and deployment of advanced, sustainable composite materials and structures, advancing the transition towards net-zero emissions and resource-efficient technologies.
As such, three research groups bring their complementary expertise to seven interconnected core research domains that form the foundation of the unit’s strategy: a comprehensive and forward-looking approach to composite engineering. From fundamental materials science to digital design and manufacturing, this strategy pursues the delivery of disruptive solutions with superior mechanical and thermal performance, enhanced recyclability and industrial scalability.
The unit develops advanced computational modelling frameworks that combine data-driven approaches with physics-based simulations across multiple scales from the material microstructure to full-scale structural components.
These predictive tools enable the virtual design and optimisation of composite materials by integrating critical factors such as microstructural behaviour, interfacial properties, manufacturing-induced variability, and long-term performance under operational loads.
By coupling artificial intelligence, machine learning, and finite element modelling, the researchers accelerate the development cycle, reduce reliance on costly physical prototyping, and support lifecycle assessment and digital twin implementation.
The unit engineers weight-efficient, high-performance composite structures by combining advanced numerical simulations with topology optimization, material tailoring and multi-objective design strategies.
The work focuses on minimizing material usage while maximizing mechanical performance, structural integrity and sustainability, even under complex loading conditions and manufacturing constraints.
Using state-of-the-art computational tools and multiscale modelling, the unit designs components that are not only lighter but also capable of withstanding demanding operational environments in aerospace, automotive, energy, and high-performance manufacturing applications. This approach enables the integration of manufacturing constraints, material anisotropy and durability requirements early in the design process, accelerating development cycles and reducing costs.
These lightweight optimisation methods and tools are essential to advancing next-generation mobility, energy efficiency, and net-zero engineering goals.
The unit aims to develop scalable, energy-efficient and environmentally responsible manufacturing processes for next-generation high-performance composites. The research spans advanced thermoset and thermoplastic systems, with a focus on enabling cost-effective production, reduced environmental footprint, and improved material circularity.
Through innovations in automated processing, reactive moulding, out-of-autoclave techniques, and thermoplastic welding, the unit addresses challenges related to cycle time reduction, process consistency, and integration of sustainability metrics.
Special attention is given to process modelling and control, allowing for predictive quality assurance and seamless scalability from lab to industrial environments. By embedding eco-design principles, recyclability, and low-emission processing into our manufacturing strategies, the researchers support the transition toward circular composite value chains and contribute to global climate and sustainability goals.
The unit conducts comprehensive experimental investigations to thoroughly characterize and validate the behaviour of composite materials under realistic and application-specific conditions.
Utilizing a wide range of advanced testing methods including mechanical, thermal, environmental testing, the researchers assess material performance across multiple scales, from fibre and matrix constituents to full composite structures.
The capabilities also include non-destructive evaluation, failure analysis and in-situ monitoring techniques, enabling accurate insight into composite material response and degradation mechanisms. These data-driven assessments not only support quality assurance and regulatory compliance but also inform design optimization, material selection and continuous product improvement across industries such as aerospace, automotive, marine, and civil engineering.
The unit focuses on the precise tailoring of interfacial properties to enhance the adhesion, durability and multifunctionality of composite materials across both micro- and macro-scales.
Recognizing that the performance of composite systems is often governed by the quality of fibre–matrix interactions, the research targets the development of functionalized interfaces that can respond to mechanical, thermal, and environmental demands. This includes innovations in surface activation, chemical modification, and nano-engineered interphases, enabling improved load transfer, damage tolerance, and environmental resistance.
The researchers also explore smart and adaptive interfaces, designed to deliver additional functionalities such as sensing, self-healing, or energy storage.
By combining experimental surface science with multi-scale modelling, this approach bridges fundamental materials research with real-world performance, supporting the design of more reliable, high-performance composite structures for demanding applications in aerospace, automotive, energy, and beyond.
Advanced additive manufacturing for composites represents a cutting-edge approach to creating complex, high-performance materials with tailored properties. This technique combines the versatility of additive manufacturing (3D printing) with the strength and functionality of composite materials, enabling the production of parts that are lightweight, durable, and optimized for specific applications.
By carefully controlling the deposition of composite materials, such as thermoset and thermoplastic resins reinforced with fibers, advanced additive manufacturing allows for the precise control of material distribution, fiber orientation, and part geometry.
This enables the creation of components with superior mechanical properties, customized shapes, and reduced material waste, making it ideal for industries such as aerospace, automotive, and construction. The integration of this technology into composite manufacturing opens new possibilities for producing complex, multi-material parts that were previously difficult or impossible to achieve with traditional manufacturing methods.
The unit specializes in the development of advanced semi-finished products that serve as the foundation for high-performance composite solutions.
This includes fibre-engineered reinforcements tailored to specific mechanical and structural requirements, as well as customized surface treatments and interface modifications to optimize bonding, durability, and functionality.
The unit’s portfolio also encompasses cutting-edge intermediate materials such as unidirectional tapes, woven fabrics, and pre-impregnated materials (pre-pregs), designed for efficient processing and enhanced performance.
These innovations play a crucial role in accelerating technological advancements across a wide range of industrial sectors, including aerospace, automotive, construction and renewable energy applications.
Three research groups bring their complementary expertise to meet the current global challenges, each contributing to the core research domains of the unit’s strategy.
The Structural Composites (SC) unit is equipped with state-of-the-art facilities that enable comprehensive research and development across all stages of composite material production, characterization, and testing. The unit benefits from access to High-Performance Computing (HPC) resources, facilitating advanced simulations and data analysis critical for optimizing composite materials and manufacturing processes. In addition to HPC, the SC Unit leverages the capabilities of the Composite Manufacturing Platform and the Materials Characterization and Testing Platform, both of which offer cutting-edge tools and techniques for material innovation and validation.
Key capabilities within the SC Unit include:
The unit features a range of advanced processing techniques that are essential for the production of high-performance composites. These include Liquid Infusion and Resin Transfer Moulding (RTM), which enable the creation of complex composite structures with precise control over material distribution.
Additionally, the unit is equipped with a Robotized Stamping Line for high-speed, large-scale composite part production and Robotic Filament Winding for the creation of custom filament-based structures. The IR Welding capability offers a versatile approach for joining composite parts, while the Robotized Cell dedicated to in-situ consolidation and automated fibre placement ensures precision and efficiency in manufacturing complex parts. The Toepreg Winding system, along with a unidirectional tape manufacturing line capable of full bath, slurry bath, and extrusion impregnation, further enhances the unit's ability to produce high-quality, tailored composite materials.
The SC Unit has access to a range of mechanical testing equipment to evaluate the performance and durability of composite materials across various scales. Nanoindentation provides insights into the hardness and stiffness of materials at the nanoscale, while Universal Testing Machines (UTMs) are used to assess mechanical properties such as tensile strength, compression, and shear. Digital Image Correlation (DIC) technology enables precise measurement of strain and displacement during mechanical testing, offering detailed insights into material behavior under load.
The SC Unit employs several non-destructive inspection techniques to evaluate the integrity and quality of composite parts without damaging them. Ultrasonic Scanning allows for the detection of internal defects, such as delaminations or voids, while CT Scanning provides detailed 3D imaging to identify potential issues within the structure.
The collaborations of the unit are a cornerstone of the unit's mission to bridge fundamental research and industrial innovation, enabling the development and deployment of next-generation composite materials and manufacturing technologies.
By engaging with partners across various sectors—ranging from aerospace and automotive to advanced materials and manufacturing—the Unit ensures its research is not only scientifically rigorous but also aligned with real-world applications and industrial needs.
More specifically, these partnerships enable:
The unit collaborates with a wide array of industry leaders to co-develop innovative solutions and accelerate technology transfer. These partnerships bring practical relevance and industrial validation to ongoing research efforts. Notable collaborations include:
Academic excellence and international scientific collaboration are essential pillars of the unit’s research strategy. These partnerships enable the co-development of knowledge, the sharing of advanced research facilities, and the supervision of joint doctoral and postdoctoral projects. Notable academic partners include:
Cellulose from waste and bacteria in electro-spinning for continuous fibre reinforced 3D printed composites
Inorganic interfacial region in ultrathin copper foil supported by copper carrier: Resolving and controlling adhesion mechanisms
Development and Optimization of Variable Cross-Section Pultrusion for the Manufacturing of High-Performance and Sustainable Composites
Vats S., Khodayari A., Mugemana C., Spirk S., Schnell C.N., Seveno D., Fuentes C.A.
Carbohydrate Polymers, vol. 381, art. no. 125204, 2026
Laachachi A., Kachouri O., Berndt J., Zucker G., Zopp C., Bartelt J., Makradi A.
Journal of Advanced Joining Processes, vol. 13, art. no. 100369, 2026
Ozyigit S., Kachouri O., Bardon J., Ruch D., Laachachi A.
Composites Part A Applied Science and Manufacturing, vol. 204, art. no. 109614, 2026
