Researchers at the National Institute of Technology (NIT) Rourkela have secured a patent for a novel composite manufacturing technology that significantly enhances the strength and durability of fibre-reinforced polymer (FRP) composites, paving the way for wider adoption in aerospace, defence, automotive, renewable energy and other high-performance engineering sectors.
The patented technology has been developed by the FRP Composite Lab in the Department of Metallurgical and Materials Engineering at NIT Rourkela through a collaborative effort involving Dr Rajesh Kumar Prusty, Assistant Professor, Prof Bankim Chandra Ray, Professor, research scholar Parimal Jana, and Dr Dinesh Kumar Rathore from the Department of Mechanical Engineering at Malaviya National Institute of Technology (MNIT) Jaipur.
Addressing a key limitation
FRP composites are widely used because of their high strength-to-weight ratio, excellent corrosion resistance, fatigue resistance and design flexibility. These lightweight yet robust materials find applications in commercial aircraft, defence platforms, space launch vehicles, high-speed rail systems, renewable energy equipment and hydrogen storage tanks.
However, conventional FRP composites are vulnerable to cracking, delamination and structural degradation when subjected to heavy mechanical stress, limiting their long-term performance in demanding environments.
Novel manufacturing process
To overcome these challenges, the NIT Rourkela-led team has developed a three-dimensional reinforced hybrid composite by integrating glass fibres with graphene nanoplatelets aligned through the thickness of the material during manufacturing.
The alignment creates a stronger internal structure, enabling the glass fibres, graphene and epoxy matrix to function more cohesively, thereby producing a composite that is tougher, more durable and better equipped to withstand mechanical damage.
A key feature of the patented technology is its ability to align unmodified graphene nanoplatelets within glass fibre-reinforced epoxy composites using a relatively simple manufacturing process. The researchers introduced only a minor modification to conventional production techniques by applying a standard 50 Hz alternating current electric field at 800 volts during the curing stage, making the innovation compatible with widely used composite manufacturing methods.
Significant performance gains
Laboratory evaluations conducted in accordance with ASTM standards demonstrated substantial improvements in the material’s mechanical properties.
The patented composite delivered a 37% increase in tensile strength, 30% improvement in flexural strength, 63% rise in flexural modulus, 26% increase in tensile modulus, and 24% improvement in interlaminar shear strength. It also achieved a 33% increase in Mode-I fracture toughness, a 53% improvement in Mode-II fracture toughness, and a 55% higher storage modulus at 40°C, indicating superior stiffness and durability under operating conditions.
Wide-ranging applications
Dr Rajesh Kumar Prusty said the technology is well suited for sectors that require lightweight yet highly damage-tolerant materials.
He said the composite can be deployed in aircraft structures, automotive crash components, wind turbine blades, pressure vessels, marine structures and a range of advanced engineering applications where durability and weight reduction are critical.
Supporting Atmanirbhar Bharat
Prof Bankim Chandra Ray said the innovation has the potential to reduce maintenance costs, improve energy efficiency and promote sustainable manufacturing by enabling the use of stronger and lighter materials.
He added that the technology could play an important role in advancing India’s Atmanirbhar Bharat mission by strengthening indigenous capabilities in advanced composite materials.
Commercialisation roadmap
The research team is now planning to evaluate the material in larger structural components and assess its long-term environmental durability under real-world operating conditions.
In parallel, the researchers are pursuing technology licensing opportunities and industry collaborations to accelerate the commercialisation of the patented technology and bring the innovation from the laboratory to the market.