Multifunctional Composites: Technical Overview and Market ... · Global market drivers in connectivity, electrification, automation, and lightweighting are all excellent pull-factors

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


About IDTechEx

IDTechEx provides clarity on emerging technologies

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2


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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

4

http://www.idtechex.com/lightaero

http://www.idtechex.com/composites


http://www.idtechex.com/composites

http://www.idtechex.com/Graphene

http://www.idtechex.com/Graphene

http://www.idtechex.com/ink

http://www.idtechex.com/ink

http://www.idtechex.com/lightweightmetals

http://www.idtechex.com/lightweightmetals

http://www.idtechex.com/barrier

http://www.idtechex.com/barrier

http://www.idtechex.com/adhesives

http://www.idtechex.com/adhesives

http://www.idtechex.com/aerogel

http://www.idtechex.com/aerogel


http://www.idtechex.com/materials

http://www.idtechex.com/Toxic

http://www.idtechex.com/Toxic

http://www.idtechex.com/perov

http://www.idtechex.com/perov

http://www.idtechex.com/qd

http://www.idtechex.com/qd

http://www.idtechex.com/structural

http://www.idtechex.com/scmats

http://www.idtechex.com/structural

http://www.idtechex.com/scmats

http://www.idtechex.com/tcf

http://www.idtechex.com/tcf

Copyright © IDTechEx. Use in accordance with distribution licence | www.IDTechEx.com slide 6

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



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


https://www.idtechex.com/research/reports/multifunctional-composites-2019-2029-technology-players-market-forecasts-000630.asp


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


Fully embedded circuitry

8


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


9



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

10


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


Complete analysis in the report:


11



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)


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.

12


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


13


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.


14


Composite de-icing applications


15

Main 4 players – technology providers

Source: Mark Kusaiha, Nordex, GKN


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

16


Complete analysis in the report: Multifunctional Composites 2019-2029



Embedded Sensor – Applications


17

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.


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.


Source: IDTechEx photos, DARPA, Stanford University, Chalmers University and Imperial College London


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


19


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


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.



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




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Dr Richard Collins

Senior Technology Analyst

[email protected]

Documents

Multifunctional Composites: Technical Overview and Market ... · Global market drivers in connectivity, electrification, automation, and lightweighting are all excellent pull-factors