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Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials
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Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 August 2026 | Viewed by 4247

Editor

Dr. Andrejs Kovalovs

E-Mail Website
Guest Editor
Institute of High-Performance Materials and Structures, Faculty of Civil and Mechanical Engineering, Riga Technical University, Kipsalas Street 6A, LV-1048 Riga, Latvia
Interests: numerical modelling; experimental testing; optimisation

Special Issue Information

Dear Colleagues,

Advanced composite materials improve the physical, thermal, mechanical, chemical, structural, environmental, and other properties of general materials and constructions in engineering science. This Special Issue of the openaccess Journal of Manufacturing and Materials Processing invites original research articles and review papers on the topic of “Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials.” Topics include innovative approaches, novel methods, and cost-effective alternatives for enhanced performance; the development of new fiber and polymer composites; the physical, chemical, mechanical, and other properties of advanced composites; experimental, theoretical and numerical studies; innovative fabrication techniques for various composite types and structural components; and design and analysis approaches for specific engineering applications. I invite researchers from all disciplines to contribute original research articles, review papers, and case studies to this Special Issue, advancing the field of advanced composite materials and manufacturing technologies.

Dr. Andrejs Kovalovs
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • engineering
  • materials
  • composites
  • synthetic fibers
  • natural fibers
  • recycled materials
  • polymers
  • biopolymers
  • additives
  • sustainability
  • experimental analysis
  • modelling/simulation
  • thermal and chemical stability
  • fatigue resistance

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (9 papers)

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Research

16 pages, 5323 KB  
Article
Sheep Wool Biochar-Enhanced HDPE Composites
by Viktoria Theodorou, Ioannis Pashalidis, Panagiotis S. Ioannou and Theodora Krasia-Christoforou
J. Manuf. Mater. Process. 2026, 10(7), 224; https://doi.org/10.3390/jmmp10070224 - 29 Jun 2026
Viewed by 239
Abstract
Animal-based biomass is gaining increasing attention in composites technology as a sustainable alternative to conventional fillers, offering a green pathway in the generation of composites exhibiting improved performance via waste valorization. In the present study, carbonized sheep wool was incorporated into high-density polyethylene [...] Read more.
Animal-based biomass is gaining increasing attention in composites technology as a sustainable alternative to conventional fillers, offering a green pathway in the generation of composites exhibiting improved performance via waste valorization. In the present study, carbonized sheep wool was incorporated into high-density polyethylene (HDPE) in various weight ratios up to 10% wt. to fabricate composite specimens. The resulting composites were evaluated through Dynamic Mechanical Analysis (DMA), while their morphology and chemical structure were investigated by Scanning Electron Microscopy (SEM) combined with Energy Dispersive X-ray Spectroscopy (SEM-EDS) and Fourier Transform Infrared Spectroscopy (FTIR), respectively. FTIR analysis revealed the presence of residual keratin-derived oxygen- and nitrogen-containing functional groups, indicating the retention of chemically active surface functionalities upon low-temperature carbonization. This evidence is further corroborated through qualitative (SEM-EDS) elemental mapping of the pristine surfaces of sheep wool fibers and the pyrolyzed biochar product. DMA experimental data demonstrated that sheep wool-derived biochar (SWB) can effectively reinforce HDPE, resulting in stiffness enhancement while reducing viscous dissipation, thereby highlighting its potential as a sustainable, eco-friendly filler and a viable pathway for circular valorization of animal biomass waste. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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16 pages, 17462 KB  
Article
3D FFF-Type Printer Upgrade for the Use of Viscous-Filled Polymeric Materials
by Karel Dvořák, Jana Dvořáková, Michal Bílek and Lucie Zárybnická
J. Manuf. Mater. Process. 2026, 10(7), 222; https://doi.org/10.3390/jmmp10070222 - 27 Jun 2026
Viewed by 275
Abstract
Recently, there has been a significant expansion of additive technologies, especially Fused Filament Fabrication (FFF). This article aims to upgrade a commercial 3D printer to develop viscous polymeric materials, as this option is not currently available. The FFF method is primarily used with [...] Read more.
Recently, there has been a significant expansion of additive technologies, especially Fused Filament Fabrication (FFF). This article aims to upgrade a commercial 3D printer to develop viscous polymeric materials, as this option is not currently available. The FFF method is primarily used with thermoplastics and elastomers in filament form. However, materials derived from various water-soluble acrylates offer significant potential, with advantages including environmental friendliness and desirable mechanical and visual properties. The possibility of using a viscous polymer as a carrier for metal material prior to sintering is also a significant factor. The aim of the text is to present the preparation of a 3D printer suitable for printing the above materials. The main requirement was to modify the selected printer with minimal interference with HW and SW. We mainly focused on adjusting the print head. A new prototype for the printing of viscous polymeric materials was visualized. Furthermore, the individual components were designed and printed; a functional system capable of processing these materials was assembled. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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20 pages, 2929 KB  
Article
Analysis of Profile and Surface Roughness of Holes Drilled in Basalt Fiber Reinforced Polymers Laminates: Statistical Analysis and Predictive Approach Based on Machine Learning
by Jorge Ayllón, Manuel Rodríguez-Martín and Rosario Domingo
J. Manuf. Mater. Process. 2026, 10(7), 221; https://doi.org/10.3390/jmmp10070221 - 26 Jun 2026
Viewed by 186
Abstract
Fiber-reinforced polymers such as basalt fiber-reinforced polymers (BFRP) can be used in structural parts, which often require assembly operations. Thus, the surface quality after drilling operations is especially important. BFRP laminates have been drilled with three different tools, and their profile roughness and [...] Read more.
Fiber-reinforced polymers such as basalt fiber-reinforced polymers (BFRP) can be used in structural parts, which often require assembly operations. Thus, the surface quality after drilling operations is especially important. BFRP laminates have been drilled with three different tools, and their profile roughness and surface roughness have been evaluated by analyzing the following variables: average roughness (Ra), maximum height of profile (Rz), arithmetic mean height (Sa) and maximum height (Sz), by means of an optical system. The optical measurement of surface roughness has been hampered by fiber breakage. A statistical analysis has allowed for developing a general linear model that predicts the values of variables. The fitted model for Ra and Rz has a variation coefficient of 97.00% and 95.58% respectively, while that 91.74% and 68.02% for Sa at the inlet hole and outlet hole respectively; and 86.08% and 82.22% for Sz at the inlet hole and outlet hole respectively. Additionally, different machine learning regression algorithms have been applied using different configurations to establish prediction models of the main rugosity parameters. In this way, linear methods, Gaussian regression methods, Support Vector Machines, and fine trees have been applied using the rotation speed, feed rates, and tool as features. Also, a neural network has been optimized and applied for the same goal. The methods yielded satisfactory prediction results within the tested experimental domain for some roughness parameters. Although the behavior of all variables is similar across all drill bit types, drill bits with a point angle of 120° provided better results. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
19 pages, 21746 KB  
Article
Influence of Deposition Strategy and Fiber Alignment on the Mechanical Anisotropy of Short-Fiber-Reinforced Polyamide Manufactured by Additive Manufacturing Material Extrusion
by Andrea Colucci, Manuela Galati and Luca Iuliano
J. Manuf. Mater. Process. 2026, 10(6), 210; https://doi.org/10.3390/jmmp10060210 - 16 Jun 2026
Viewed by 404
Abstract
Short-fiber-reinforced composites (SFRCs) are widely used for their high strength-to-weight ratio. In the Additive Manufacturing (AM) field, Material Extrusion (MEX) processes inherently induce anisotropy, primarily due to fiber alignment along the deposition path, making printing direction and layer orientation critical for mechanical performance. [...] Read more.
Short-fiber-reinforced composites (SFRCs) are widely used for their high strength-to-weight ratio. In the Additive Manufacturing (AM) field, Material Extrusion (MEX) processes inherently induce anisotropy, primarily due to fiber alignment along the deposition path, making printing direction and layer orientation critical for mechanical performance. In this study, specimens made of Onyx®, a carbon short-fiber-reinforced polyamide, were fabricated by varying their orientation on the build platform, thereby producing different infill deposition directions. Each replica contained 25 layers. Two deposition strategies were investigated: a conventional alternating ±45° raster pattern and a 0°/90° configuration. Owing to the odd number of deposited layers, the latter resulted in two distinct stacking configurations, namely 0°/90° and 90°/0°, depending on the orientation of the first deposited layer. With such a strategy, it was possible to obtain configurations with a predominance of fibers either aligned with or transverse to the loading direction, depending on the orientation of the first-deposited layer. Mechanical test results were systematically compared to evaluate the influence of deposition strategy and fiber orientation on tensile performances. The effect of extrusion on fiber alignment was evaluated using Scanning Electron Microscopy (SEM). Mechanical behavior was evaluated using replicated tensile testing (five specimens per condition) and SEM-based fiber-orientation analysis. The investigation confirms the anisotropic nature of MEX-produced SFRCs. In particular, the 0°/90° configuration showed reductions of approximately 24% in tensile strength and 58% in elongation at break compared with the ±45° configuration. These results demonstrate that both extrusion-induced fiber orientation and layer-wise deposition strategy play a crucial role in defining the mechanical response of the material. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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28 pages, 9487 KB  
Article
Multi-Objective Optimization of a Composite FRP Laminated Sandwich Structure Using Artificial Neural Network and Particle Swarm Optimization Algorithm
by Muhammad Ali Sadiq and György Kovács
J. Manuf. Mater. Process. 2026, 10(6), 203; https://doi.org/10.3390/jmmp10060203 - 11 Jun 2026
Viewed by 433
Abstract
Designing lightweight composite sandwich structures is challenging due to the conflicting objectives of minimizing structural weight and cost while satisfying strength and stiffness requirements. The optimization procedure becomes more complex when multiple discrete design variables and nonlinear material behavior are involved. This study [...] Read more.
Designing lightweight composite sandwich structures is challenging due to the conflicting objectives of minimizing structural weight and cost while satisfying strength and stiffness requirements. The optimization procedure becomes more complex when multiple discrete design variables and nonlinear material behavior are involved. This study presents a newly developed optimization methodology for a sandwich structure composed of Fiber Reinforced Polymer (FRP) laminated facesheets and an aluminum honeycomb core. To reduce the computational cost associated with repeated high-fidelity Finite Element (FE) analyses, a surrogate modeling strategy based on Artificial Neural Networks (ANNs) is employed to approximate the structural response. The applied dataset is generated using Monte Carlo simulation in which combinations of design variables are used as inputs, and the corresponding structural responses obtained from the analytical formulation are used as outputs for training the ANN surrogate model. The trained ANN model is integrated with a Multi-Objective Niching Memetic Particle Swarm Optimization (MO-NMPSO) algorithm to simultaneously minimize structural weight and material cost while satisfying constraints on facesheet strength, wrinkling, intra-cell buckling, deflection, core shear failure and structural thickness. The resulting Pareto-optimal solutions are validated through detailed FE simulations, demonstrating the reliability of the newly elaborated optimization framework. The results of the newly developed computationally efficient optimization procedure provide a diverse set of optimal design solutions for the investigated sandwich structure. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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26 pages, 4784 KB  
Article
Microstructural Diversity in Dispersed Composites Governed by Inclusion Distribution
by Vladimir Mityushev, Pawel Kurtyka, Zhanat Zhunussova and Akylkerey Sarvarov
J. Manuf. Mater. Process. 2026, 10(6), 202; https://doi.org/10.3390/jmmp10060202 - 10 Jun 2026
Viewed by 391
Abstract
The microstructure of metal matrix composites is inherently governed by fabrication routes and processing parameters, yet technological and physical constraints often prevent the realization of intended structural designs. In particle-reinforced composites produced via casting, interactions between the solidification front and inclusions frequently lead [...] Read more.
The microstructure of metal matrix composites is inherently governed by fabrication routes and processing parameters, yet technological and physical constraints often prevent the realization of intended structural designs. In particle-reinforced composites produced via casting, interactions between the solidification front and inclusions frequently lead to agglomeration, segregation, and hence, a non-uniform distribution of the inclusions concentration. To mitigate these effects, post-processing techniques such as Friction Stir Processing offering particular promise for cast materials by refining microstructures and enhancing phase homogeneity. This study addresses these challenges by application of Fourier transform analysis to characterize stochastic inclusion distributions. Building on the Windows Washing method, we extend its application to heterogeneous media with varying inclusion concentrations. Through computer simulations and experimental analysis of real composites, we demonstrate that discrete Fourier transform can reveal hidden stochastic periodicity. The proposed framework provides a pathway toward improved predictive models and optimization strategies for metal matrix composites processing and performance. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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14 pages, 912 KB  
Article
Comparative Life Cycle Assessment of Hull Manufacturing for Small-Size Crafts
by Paolo De Sio, Vittorio Rosanova, Vitantonio Esperto, Antonello Astarita and Fausto Tucci
J. Manuf. Mater. Process. 2026, 10(6), 192; https://doi.org/10.3390/jmmp10060192 - 30 May 2026
Viewed by 441
Abstract
In recent years, environmental sustainability has become a key issue in the shipbuilding industry, driving research towards a reduction in the environmental impact throughout the entire life cycle of vessels. In this context, composite materials are a solid alternative to achieve mechanical performance [...] Read more.
In recent years, environmental sustainability has become a key issue in the shipbuilding industry, driving research towards a reduction in the environmental impact throughout the entire life cycle of vessels. In this context, composite materials are a solid alternative to achieve mechanical performance optimization and energy consumption reduction. This study compares two hull configurations, one in a glass fiber-reinforced thermoset composite and one in a thermoplastic composite sandwich structure, through life cycle assessment. The aim is to assess the influence of material choice and structural configuration on overall environmental impacts by analyzing energy and material inputs and emissions throughout the entire life cycle, from “cradle to grave” excluding the end-of-life treatment. The results evidence a 36% average reduction in the impact categories analyzed. Moreover, economic benefits emerged, with a 35% reduction in the cost of energy required during the analyzed life cycle phases and 9% reduction in the material supply. This work aims to contribute to the definition of more sustainable design strategies to produce hulls and naval components, promoting a transition towards a more efficient and environmentally friendly nautical sector. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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29 pages, 18319 KB  
Article
Effect of Porosity and Post-Processing on the Mechanical Performance of Additively Manufactured PEEK Osteoconductive Scaffolds
by Samreen Dallal, Babak Eslami and Saeed Tiari
J. Manuf. Mater. Process. 2026, 10(6), 187; https://doi.org/10.3390/jmmp10060187 - 29 May 2026
Viewed by 430
Abstract
Additive manufacturing enables the fabrication of porous polyetheretherketone (PEEK) structures with controlled architectures for biomedical applications. In particular, porous PEEK scaffolds have attracted significant attention due to their potential to enhance osteoconductivity while maintaining mechanical compatibility with bone. However, the relationship between porosity, [...] Read more.
Additive manufacturing enables the fabrication of porous polyetheretherketone (PEEK) structures with controlled architectures for biomedical applications. In particular, porous PEEK scaffolds have attracted significant attention due to their potential to enhance osteoconductivity while maintaining mechanical compatibility with bone. However, the relationship between porosity, post-processing conditions, and mechanical performance remains insufficiently understood, especially at high porosity levels. In this study, the effects of porosity (49–81%) and post-processing heat treatment (4 and 6 h at 300 °C) on the mechanical performance of additively manufactured PEEK osteoconductive scaffolds were experimentally investigated. Compression and three-point bending tests were conducted to evaluate strength and elastic modulus. Results demonstrated a strong inverse relationship between porosity and mechanical properties, with significant reductions observed beyond critical thresholds of approximately 66% in compression and 59% in bending. Heat treatment improved mechanical performance at lower porosity levels, likely due to enhanced crystallinity and interlayer bonding, while its effect diminished at higher porosities due to reduced load-bearing material and ligament thinning. These findings highlight the importance of optimizing porosity and post-processing conditions to achieve a balance between mechanical integrity and osteoconductive potential in PEEK scaffolds. The results provide practical design guidelines for the development of additively manufactured PEEK structures for load-bearing orthopedic applications. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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9 pages, 1926 KB  
Article
Effect of Aluminum Powder Agglomeration on the Foaming of Al-TiH2 Bulk Foamable Precursors
by Dominic Malanga, Oscar Osuna and K. Morsi
J. Manuf. Mater. Process. 2026, 10(5), 176; https://doi.org/10.3390/jmmp10050176 - 16 May 2026
Viewed by 707
Abstract
The powder metallurgy route (PM route) for producing aluminum closed-cell foams has recently attracted significant scientific and industrial interest. The process involves mixing a blowing agent powder (e.g., TiH2) with aluminum powder, then compacting the mixture to produce a high-density bulk [...] Read more.
The powder metallurgy route (PM route) for producing aluminum closed-cell foams has recently attracted significant scientific and industrial interest. The process involves mixing a blowing agent powder (e.g., TiH2) with aluminum powder, then compacting the mixture to produce a high-density bulk foamable precursor (BFP). The BFP is then heated above the melting point of aluminum, where the hydrogen released from TiH2 particles forms bubbles in the molten aluminum, which become closed pores (cells) upon solidification. Despite metal powder agglomeration being an important factor in powder metallurgy research that can significantly influence processing, it has surprisingly received little to no attention in the powder-based foaming of metals. To the best of our knowledge, this paper is the first to address aluminum powder agglomeration within the context of powder-based metallic foams. Results show that significant aluminum powder agglomeration not only leads to an inhomogeneous distribution of the TiH2 particles within the BFP, but also to the formation of locally higher than nominal concentrations of TiH2 particle-rich regions, which greatly influence foaming characteristics. The work, for the first time, highlights the need to seriously consider metal-powder agglomeration (even partial agglomeration) in future foaming research via the PM route, and its effect on foaming characteristics. Full article
(This article belongs to the Special Issue Processing, Mechanical Properties, and Manufacturing Techniques of Advanced Composite Materials)
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