Advanced Composites Manufacturing and Plastics Processing, 2nd Volume

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Topic Information

Dear Colleagues,

Environmental and energy concerns and digitalization are currently having profound effects in reshaping the plastics and composites industry. Manufacturing processes and systems evolve accordingly in order to cost-effectively produce high-performance, high-quality, lightweight, and multifunctional parts with a reduced carbon footprint. All composites manufacturing and polymer processing technologies are concerned with this trend: liquid composite molding (e.g., resin transfer molding and resin infusion/vacuum infusion), automated lay-up (e.g., automated fiber placement and automated tape laying), filament winding, prepreg technology, pultrusion, autoclave, compression molding, film stacking, additive manufacturing/3D printing, injection molding, over-molding/back-molding, extrusion, blow molding, thermoforming, rotational molding, foaming, coating, preforming of textile reinforcement, joining/welding, and mold technologies (i.e., mold making and design).

Following the previous Topic (Advanced Composites Manufacturing and Plastics Processing), this new Topic welcomes original research articles, state-of-the-art reviews, and short communications on the latest advances in composites manufacturing and plastics processing. Suggested contributions may address new process developments, modeling/simulation, monitoring/control, and performance or application issues, with either experimental or numerical approaches. All types of polymers (thermoplastics, thermosets, and elastomers) and fibers/fillers (glass, carbon, ceramic, mineral, and vegetal) are eligible topics of focus, whether they come from recycled, bio-based, or fossil feedstocks. Multidisciplinarity is also encouraged to cover emerging topics such as smart manufacturing, artificial intelligence applied to manufacturing, data-driven simulations, and digital twins.

Prof. Dr. Patricia Krawczak
Prof. Dr. Ludwig Cardon
Prof. Dr. Frederik Desplentere
Topic Editors

Keywords

Participating Journals

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Fibers fibers	4.2	7.3	2013	19.7 Days	CHF 2000	Submit
Journal of Composites Science jcs	4.6	6.7	2017	13.9 Days	CHF 1800	Submit
Journal of Manufacturing and Materials Processing jmmp	4.0	5.7	2017	13.7 Days	CHF 1800	Submit
Materials materials	3.7	7.0	2008	14.4 Days	CHF 2600	Submit
Polymers polymers	5.8	11.0	2009	13.4 Days	CHF 2700	Submit
Recycling recycling	5.2	7.5	2016	19.4 Days	CHF 1800	Submit

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Published Papers (10 papers)

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All Fibers J. Compos. Sci. JMMP Materials Polymers Recycling

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56 pages, 7632 KB  

Open AccessReview

Research Progress on Advanced Molding Technologies for Carbon Fiber-Reinforced Polymer Composites: Defect Control and Process Optimization

by Qun Li, Xufeng Song, Longzhan Zheng, Guangxi Li, Qingqing Lü, Liquan Yang, Erbo Liu, Yuqin Ma and Zhoukui Li

Fibers 2026, 14(6), 69; https://doi.org/10.3390/fib14060069 - 8 Jun 2026

Viewed by 2274

Abstract

Carbon fiber-reinforced polymer (CFRP) composites are in urgent demand in the aerospace, new energy vehicle, and wind power sectors owing to their superior specific strength, specific modulus, and lightweight potential. However, molding defects, such as voids, dry spots, and delamination, arising from their [...] Read more.

Carbon fiber-reinforced polymer (CFRP) composites are in urgent demand in the aerospace, new energy vehicle, and wind power sectors owing to their superior specific strength, specific modulus, and lightweight potential. However, molding defects, such as voids, dry spots, and delamination, arising from their anisotropy and weak interlaminar bonding, severely constrain their service performance. Advanced molding technologies represent the key to overcoming this bottleneck. This paper systematically reviews typical advanced molding technologies in the field of CFRP composites, including resin transfer molding (RTM) and vacuum-assisted resin transfer molding (VARTM) in liquid composite molding, autoclave molding and compression molding (CM) in prepreg molding, and automated fiber placement (AFP) and material extrusion (ME) in automated molding. From an integrated perspective of “technological evolution–process characteristics–defect mechanisms–optimization strategies,” this review summarizes the technical principles, development trajectories, and core advantages of each process, analyzes the formation mechanisms of typical defects, including voids, dry spots, delamination, wrinkles, warpage, and melt instability, and summarizes multidimensional optimization advances in process parameter regulation, numerical simulation, resin modification, equipment upgrading, path planning, and thermal management. Furthermore, the differences and complementarities among these processes in terms of molding precision, efficiency, cost, and applicable scope are compared. Finally, future development directions, including digital twins, green low-carbon manufacturing, ultra-large integrated structures, multi-process integration, standardized defect characterization, and low-cost collaborative design, are discussed. This paper aims to provide systematic theoretical references and technical support for the optimization and upgrading, process integration, and industrial application of advanced CFRP molding technologies. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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15 pages, 8935 KB  

Open AccessArticle

Strong, Biodegradable Lignocellulosic Films as Potential Bioplastics

by Zhenzhen Zhang, Ziyu Duan, Juan Wang, Jungang Jiang, Zhishun Wei, Silong Wu and Jan-Michael Albina

Polymers 2026, 18(11), 1359; https://doi.org/10.3390/polym18111359 - 29 May 2026

Cited by 1 | Viewed by 830

Abstract

Lignocellulosic films (LCFs) derived from biomass have attracted increasing attention owing to their abundant availability, recyclability, and biodegradability, making them promising candidates for replacing non-biodegradable plastics. Notably, the mechanical properties and wet stability of these materials play a crucial role in their practical [...] Read more.

Lignocellulosic films (LCFs) derived from biomass have attracted increasing attention owing to their abundant availability, recyclability, and biodegradability, making them promising candidates for replacing non-biodegradable plastics. Notably, the mechanical properties and wet stability of these materials play a crucial role in their practical applications. In this paper, we employ an eco-friendly and straightforward approach to synthesizing high-strength LCF by mixing nanocellulose with lignin. The incorporation of lignin enhances the mechanical strength for LCF, achieving a yield strength of 157.12 MPa at a lignin content of 15 wt% while simultaneously imparting excellent water absorption properties. Fourier transform infrared (FTIR) and contact angle measurements confirmed the structural integrity and hydrophilicity of the composite films. Excessive lignin content led to reduced mechanical performance, emphasizing the importance of optimizing the lignin-to-cellulose ratio. Therefore, this paper demonstrates the significant potential of LCF in developing environmentally friendly materials for applications in water treatment, packaging, flexible electronics, energy storage, and agriculture. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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27 pages, 12850 KB  

Open AccessArticle

Multi-Objective Optimization of the Dry Towpreg Filament Winding Process for Carbon/Epoxy Type IV Hydrogen Storage Vessels

by Ruiqi Li, Kaidong Zheng, Xiaoyu Yan, Haonan Liu, Yu Zhang, Guangming Huo, Haixiao Hu, Dongfeng Cao, Hao Li, Hongda Chen and Shuxin Li

Polymers 2026, 18(5), 639; https://doi.org/10.3390/polym18050639 - 5 Mar 2026

Viewed by 1591

Abstract

Hydrogen storage vessels are critical components in hydrogen energy systems, and improving their manufacturing efficiency and structural performance is essential for next-generation Type IV vessel designs. Compared with conventional wet filament winding, towpreg dry filament winding offers higher efficiency, reduced environmental impact, and [...] Read more.

Hydrogen storage vessels are critical components in hydrogen energy systems, and improving their manufacturing efficiency and structural performance is essential for next-generation Type IV vessel designs. Compared with conventional wet filament winding, towpreg dry filament winding offers higher efficiency, reduced environmental impact, and better adaptability to complex structures. In this study, key process parameters, including winding tension, heating temperature, and winding speed were systematically optimized using the tensile strength and interlaminar shear strength of NOL ring specimens as evaluation metrics. A response surface methodology (RSM) regression model was established to correlate process variables with mechanical properties, followed by multi-objective optimization using the non-dominated sorting genetic algorithm II (NSGA-II) and final parameter selection through the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. The results indicate that shear strength is primarily affected by heating temperature, whereas tensile strength is mainly governed by winding tension. The optimal parameter combination (79 N, 360 °C, and 11 m/min) yielded tensile and shear strengths of 2462.2 MPa and 64.4 MPa, respectively, with prediction errors below 0.5%. A 9 L Type IV hydrogen storage vessel manufactured under these conditions showed approximately 15.4% lower mass and about 17% higher gravimetric hydrogen storage efficiency than a comparable wet wound vessel. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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23 pages, 1772 KB  

Open AccessArticle

Experimental Study on Drilling Performance of Bio-Waste-Based Corn Husk Fiber Reinforced Epoxy Composites for Green Applications

by Karthick Rasu, Ashwin Prabhu Gnanasekaran, Sudarsan Deenadayalan, Kuntanahal Rajashekhara, Kamalakannan Ranganathan and Joao Paulo Davim

J. Manuf. Mater. Process. 2026, 10(2), 74; https://doi.org/10.3390/jmmp10020074 - 21 Feb 2026

Viewed by 1181

Abstract

This study focuses on the machinability optimization of bio-waste corn husk fiber–reinforced epoxy composites during drilling, with the objective of minimizing delamination and improving hole quality required for mechanical fastening applications. While natural fiber composites have been widely investigated, systematic statistical optimization of [...] Read more.

This study focuses on the machinability optimization of bio-waste corn husk fiber–reinforced epoxy composites during drilling, with the objective of minimizing delamination and improving hole quality required for mechanical fastening applications. While natural fiber composites have been widely investigated, systematic statistical optimization of drilling parameters for corn husk fiber composites remains limited. The novelty of this work lies in identifying the dominant drilling parameter and establishing a clear damage-control strategy using a Taguchi L16 design coupled with ANOVA. Drilling experiments were conducted by varying spindle speed (1000, 1500, 2000, and 2500 rpm), drill diameter (6, 8, 10, and 12 mm), feed rate (00.05, 0.10, 0.15, and 0.20 mm/rev), and point angle (90°, 100°, 110°, and 120°). The results show that the drill diameter is the governing factor affecting delamination, contributing 73.52% of the total variation, followed by spindle speed (22.68%), whereas feed rate (3.14%) and point angle (0.38%) have minimal influence. The optimal condition (2500 rpm, 6 mm drill diameter, and 0.05 mm/rev feed rate) produced the lowest delamination and improved surface integrity. Microscopic observations confirmed reduced fiber pull-out and matrix cracking under these conditions. The main advantage of the proposed approach is the clear identification of parameter priority, enabling the industry to control drilling damage by primarily selecting appropriate drill diameter and spindle speed. The findings provide practical machining guidelines for the use of corn husk fiber composites in lightweight panels, automotive interior parts, and secondary structural components where reliable bolted joints are required. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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17 pages, 2539 KB  

Open AccessArticle

Dynamic Characterization and Damping Enhancement Mechanism of Carbon Fiber Reinforced Hybrid Structures for Aerospace Electronics

by Jun Rao, Qiaoxin Zhang, Yu Feng, Meng Wei and Wentao Yang

Polymers 2026, 18(4), 516; https://doi.org/10.3390/polym18040516 - 19 Feb 2026

Viewed by 954

Abstract

In modern aerospace cockpits, the display and control console (DCC) serves as a critical human–machine interface. Light weight is particularly important in this industry, especially for key equipment such as the DCC. To address the excessive weight of aluminum alloy DCCs while achieving [...] Read more.

In modern aerospace cockpits, the display and control console (DCC) serves as a critical human–machine interface. Light weight is particularly important in this industry, especially for key equipment such as the DCC. To address the excessive weight of aluminum alloy DCCs while achieving desirable mechanical properties and vibration-damping performance, this study developed a Carbon Fiber Reinforced Polymer (CFRP) DCC; its superior performance was verified through finite element analysis (FEA) and a vibration test. Compared with conventional aluminum alloy structures, the newly designed DCC achieves approximately a 40% weight reduction while meeting all rigidity, strength, and vibration requirements. This study successfully demonstrates the feasibility of using CFRP to replace aluminum alloy in aircraft DCC and provides a systematic design methodology for similar structures. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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12 pages, 2238 KB  

Open AccessArticle

Preparation of an ABS-ZnO Composite for 3D Printing and the Influence of Printing Process on Printing Quality

by Chao Du, Yali Zhao and Yong Li

Fibers 2026, 14(2), 19; https://doi.org/10.3390/fib14020019 - 2 Feb 2026

Cited by 1 | Viewed by 1498

Abstract

In this study, the process of preparing ABS-ZnO (Acrylonitrile Butadiene Styrene-Zinc Oxide) composite materials as FDM printing materials was elaborated, and the influence of printing process parameters on the tensile properties and surface roughness of the materials was analyzed. It was concluded through [...] Read more.

In this study, the process of preparing ABS-ZnO (Acrylonitrile Butadiene Styrene-Zinc Oxide) composite materials as FDM printing materials was elaborated, and the influence of printing process parameters on the tensile properties and surface roughness of the materials was analyzed. It was concluded through orthogonal experiments that among all the parameters studied, the infill rate had the most significant effect on the tensile strength, followed by layer thickness and layer width, while the printing speed had the least effect. When the printing parameters were set as follows: infill rate (90%), layer thickness (0.2 mm), layer width (0.4 mm), and printing speed (200 mm/s), the tensile strength of the sample reached the maximum value of 48.37 MPa. Scanning electron microscopy (SEM) analysis revealed that a high infill rate could make the internal structure of the material denser and the bonding between fibers more sufficient. In contrast, with the increase in layer thickness and layer width, the internal structure of the material exhibited a porous morphology, which led to a decrease in tensile properties. By investigating the effects of printing temperature and layer thickness on the surface roughness of the samples, the optimal surface roughness was achieved when the printing temperature was set at 230 °C, and the layer thickness was 0.3 mm. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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16 pages, 2316 KB  

Open AccessArticle

A Temperature-Dependent Visco-Hyperelastic Constitutive Model for Carbon Fiber/Polypropylene Prepreg

by Haochen Zhu and Mingrui Liu

J. Compos. Sci. 2026, 10(1), 12; https://doi.org/10.3390/jcs10010012 - 1 Jan 2026

Viewed by 764

Abstract

This study first heat-treats the surface of plain-woven carbon fibers to remove the surface sizing. The treated carbon fibers were then hot-pressed with polypropylene films to produce a carbon fiber/polypropylene prepreg. The resulting prepreg was subjected to uniaxial and off-axis tensile tests, providing [...] Read more.

This study first heat-treats the surface of plain-woven carbon fibers to remove the surface sizing. The treated carbon fibers were then hot-pressed with polypropylene films to produce a carbon fiber/polypropylene prepreg. The resulting prepreg was subjected to uniaxial and off-axis tensile tests, providing fundamental data for constructing a constitute model for the carbon fiber/polypropylene prepreg. The relative error between the model predictions and experimental data is maintained within ±10%. Based on the experimental results, a temperature-dependent viscoelastic–hyperelastic constitutive model for carbon fiber/polypropylene is proposed. This model decomposes the unit volume strain energy function into four components: matrix isochoric deformation energy, fiber tensile strain energy, fiber–fiber shear strain energy, and fiber-matrix shear strain energy. The matrix energy is strain rate-dependent, exhibiting viscoelastic mechanical behavior. The material parameters of the constitutive model were identified by fitting the experimental data. The model was implemented in MATLABR2024a, and off-axis tensile tests were performed at temperatures ranging from 423 K to 453 K. Numerical simulations were compared with experimental results to validate the model. This work provides guidance for the development and validation of constitutive models for thermoplastic polypropylene prepregs. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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17 pages, 2720 KB  

Open AccessArticle

The Influence of Microstructural Heterogeneities on the Thermal Response of CFRTP Composite Tapes at the Ply-Scale

by Mabel Palacios and Anaïs Barasinski

J. Compos. Sci. 2025, 9(11), 617; https://doi.org/10.3390/jcs9110617 - 9 Nov 2025

Cited by 1 | Viewed by 932

Abstract

The thermal response of Carbon Fiber Reinforced Thermoplastic (CFRTP) tapes under short-term localized heating is critical for automated manufacturing processes. Conventional homogenized models often overlook microstructural heterogeneities that can promote non-uniform heating and affect the quality of the consolidated part. In this work, [...] Read more.

The thermal response of Carbon Fiber Reinforced Thermoplastic (CFRTP) tapes under short-term localized heating is critical for automated manufacturing processes. Conventional homogenized models often overlook microstructural heterogeneities that can promote non-uniform heating and affect the quality of the consolidated part. In this work, we combine insights from infrared thermography with finite element simulations at the fiber scale built on micrographs extracted from real tapes to quantify the effect of individual heterogeneities—including surface roughness, thickness variation, fiber agglomeration, and porosity—on thermal propagation. Three modeling configurations were compared under identical conditions: a full microstructure model; a simplified geometry-aware model (where the real geometry is taken into the account, including the surface roughness and thickness variability, but the properties of the domain are considered as a homogeneous-equivalent material); and a homogeneous-equivalent baseline with flat borders and uniform thickness. Results show that porosity effects depend strongly on location and orientation: large, horizontally aligned pores near the heated surface produce the highest gradients. Surface roughness, on the other hand, exerts dominant effects on surface temperature non-uniformity with respect to thickness variation and fiber distribution. These findings demonstrate that accounting for microscale heterogeneities is essential to achieve more accurate, optimized, and application-tailored analyses of CFRTP tapes in advanced manufacturing. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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22 pages, 3491 KB  

Open AccessArticle

Evaluation of Bond Strength in Multi-Material Specimens Using a Consumer-Grade LCD 3D Printer

by Shunpei Shimizu, Masaya Inada, Tomoya Aoba, Haruka Tamagawa, Yuichiro Aoki, Masashi Sekine and Sumihisa Orita

J. Manuf. Mater. Process. 2025, 9(10), 332; https://doi.org/10.3390/jmmp9100332 - 11 Oct 2025

Viewed by 2254

Abstract

Additive Manufacturing (AM) is currently widely used as a means of production and processing. Among the techniques, stereolithography 3D printers (3DP) are highly accurate and versatile, making them popular for personal use. While many personal 3D printers with multi-material printing capabilities have appeared [...] Read more.

Additive Manufacturing (AM) is currently widely used as a means of production and processing. Among the techniques, stereolithography 3D printers (3DP) are highly accurate and versatile, making them popular for personal use. While many personal 3D printers with multi-material printing capabilities have appeared on the market, stereolithography printers for personal use have yet to appear. Therefore, assuming the realization of a low-cost, versatile 3D printer with this functionality, we verified whether the resins currently available for personal use are suitable for this functionality by conducting printing, secondary curing, and tensile tests. The printing results showed that all test specimens were printed with an exposure time of 8 s or more. The tensile test results indicated that the test specimens produced by multi-material printing exhibited tensile strength comparable to that of single-material specimens (90% to 114% of the weak material standard). Additionally, it was confirmed that strength manipulation and post-processing are possible with multi-material printing using the same printing parameters. These findings demonstrate that multi-material printing using conventional commercially available resins is sufficiently practical in terms of strength. The use of existing resins and low-cost photopolymerization-based 3D printers contributes to the realization of low-cost yet high-precision AM technology. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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19 pages, 1347 KB  

Open AccessArticle

Virtual Sensor for Injection Molding Monitoring

by Ronan Le Goff, Sabine Belle, Armelle Chenu, Nils Marchal, Antoine Delacourt, Franck Sellier and Matthieu Ponchant

J. Manuf. Mater. Process. 2025, 9(9), 311; https://doi.org/10.3390/jmmp9090311 - 9 Sep 2025

Viewed by 3122

Abstract

Monitoring the complete injection molding process is becoming critical for manufacturing high-quality polymer products, as it enhances product quality and process efficiency. This study presents the development of a virtual sensor designed to monitor critical parameters of the injection molding process that cannot [...] Read more.

Monitoring the complete injection molding process is becoming critical for manufacturing high-quality polymer products, as it enhances product quality and process efficiency. This study presents the development of a virtual sensor designed to monitor critical parameters of the injection molding process that cannot be measured with existing sensors. The virtual sensor integrates both one-dimensional system simulations and data-driven models to accurately predict the behavior of the complete injection molding process, including the plasticizing steps. In our investigation, the virtual sensor was tested and demonstrated its ability in forecasting key process parameters, namely the injection pressure and the screw displacement. The sensor’s ability to provide real-time melt temperature or shear rate highlights its practical applicability and effectiveness in optimizing the injection molding process. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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