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Advanced Manufacturing of Lightweight Structures: Forming, Simulation, and Green Composites

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 10 December 2026 | Viewed by 1205

Editor


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Guest Editor
Department of Chemical, Materials and Production Engineering, University of Naples Federico II, P.le V. Tecchio 80, 80125 Napoli, Italy
Interests: composite materials; metals; metal foams; polymers; natural fibers; forming processes; FEM simulations; materials characterization
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Special Issue Information

Dear Colleagues,

In recent years, the domain of lightweight structures has experienced remarkable progress. Currently, applications span a wide array of sectors, from aerospace and automotive engineering to civil construction and high-performance sporting equipment, where advanced structural solutions are reshaping industrial practices by delivering high strength combined with reduced mass.

A particularly dynamic area within this field concerns the adoption of green composite materials as alternatives to traditional synthetic composites. These materials are increasingly viewed as advanced fourth‑generation engineered composites, owing to their advantageous properties such as intrinsic composability, environmental compatibility, and the overall biodegradability of end products. As a result, they have attracted growing interest within both academic and industrial communities.

This Special Issue, titled “Advanced Manufacturing of Lightweight Structures: Forming, Simulation, and Green Composites”, aims to deepen the understanding of key principles governing lightweight structures and to provide a comprehensive reference for researchers, engineers, and practitioners interested in leveraging the potential of these materials. This Special Issue welcomes contributions addressing, but not limited to, the following topics:

  • The role of lightweight materials, particularly green composites, in the design of energy-efficient systems;
  • Recent advancements, emerging trends, and engineering applications in the field of lightweight structural solutions;
  • Thermomechanical characterization of green composite systems;
  • Forming technologies and processing routes employed in the manufacturing of advanced lightweight materials;
  • End-of-life assessment of lightweight structures within the circular economy framework;
  • Development of specialized material models and corresponding thermomechanical simulations.

Dr. Antonio Formisano
Guest Editor

Manuscript Submission Information

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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. Materials is an international peer-reviewed open access semimonthly 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 2600 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

  • lightweight structures
  • green composites
  • advanced manufacturing
  • thermomechanical properties
  • modeling and simulation
  • recycling
  • end-of-life

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Published Papers (2 papers)

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Research

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13 pages, 2557 KB  
Article
Numerical Modeling Strategies in Flax Fiber-Reinforced Polypropylene Forming Processes
by Antonio Formisano, Ilaria Improta and Giuseppe Irace
Materials 2026, 19(15), 3254; https://doi.org/10.3390/ma19153254 - 1 Aug 2026
Viewed by 240
Abstract
Natural fiber-reinforced thermoplastic composites have gained increasing attention due to the abundant availability of natural fibers, their ability to effectively reinforce polymer matrices, and the resulting partial biodegradability of the final material. This study presents numerical modeling strategies for investigating the manufacture of [...] Read more.
Natural fiber-reinforced thermoplastic composites have gained increasing attention due to the abundant availability of natural fibers, their ability to effectively reinforce polymer matrices, and the resulting partial biodegradability of the final material. This study presents numerical modeling strategies for investigating the manufacture of spherical caps made from polypropylene composites reinforced with woven flax fabrics. The investigation considers both cold incremental forming and stretch-forming processes, performed either with or without the support of a partial counter die. Building on the findings of a previous experimental study conducted by the authors on compression-molded laminates manufactured using untreated woven flax fabrics and without coupling agents and formed without localized heating, numerical predictions are compared with experimental results in terms of final geometry, forming forces, and failure mechanisms. The findings highlight the need for a thorough understanding of material behavior to fully exploit finite element analysis as a reliable predictive tool in the forming of these innovative lightweight composite structures. Full article
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Review

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52 pages, 10755 KB  
Review
Recent Trends in Manufacturing of Thermoplastic Sandwich Structures: A Review
by Amal Alliyankal Vijayakumar, Muhammad Zahid, Stefano G. Corvaglia, Francesca Lionetto and Alfonso Maffezzoli
Materials 2026, 19(10), 2077; https://doi.org/10.3390/ma19102077 - 15 May 2026
Cited by 2 | Viewed by 684
Abstract
Lightweight thermoplastic sandwich structures have a potential in terms of high specific strength, recyclability, repairability, and reduced manufacturing costs and cycle times, thereby widening their applicability in the aviation industry. However, joining thermoplastic skins to the core is considered a critical process in [...] Read more.
Lightweight thermoplastic sandwich structures have a potential in terms of high specific strength, recyclability, repairability, and reduced manufacturing costs and cycle times, thereby widening their applicability in the aviation industry. However, joining thermoplastic skins to the core is considered a critical process in determining the structural integrity of fully recyclable sandwich systems. Despite rapid technological progress, a comprehensive assessment of manufacturing routes capable of achieving reliable skin/core fusion bonding remains lacking. Therefore, this review critically examines manufacturing techniques for thermoplastic-based sandwich panels, with particular emphasis on advanced processes that achieve effective skin/core fusion bonding. Within conventional manufacturing routes, compression moulding and double-belt lamination have the potential for high-volume production and process automation. Skin/core fusion bonding via in situ core formation enhances manufacturing flexibility, particularly for achieving complex designs. Emerging approaches, including additive manufacturing, automated fibre placement, and welding-based methods, are identified as promising fusion-bonding strategies. This offers enhanced manufacturing simplicity and efficiency by minimising interlinked processing stages and eliminating the need for intricate mould patterns. Future advancements are expected to focus on highly integrated and scalable manufacturing routes capable of simultaneously achieving skin consolidation, in situ core formation, and skin/core fusion bonding within a single process. In particular, continuous welding-assisted manufacturing and additive manufacturing-based approaches are highlighted as promising pathways for improving structural integration, recyclability, and production efficiency in next-generation thermoplastic sandwich structures. Overall, this review provides a structured foundation to guide future research directions and support the development of more efficient, scalable, and structurally reliable thermoplastic sandwich manufacturing technologies. Full article
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