Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends

Girmay Mengesha Aznaw

doi:doi:10.11648/j.cm.20250901.11

Review Article |

| Peer-Reviewed

Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends

Girmay Mengesha Aznaw^*

Published in Composite Materials (Volume 9, Issue 1)

Received: 7 November 2024 Accepted: 6 December 2024 Published: 7 January 2025

Views: Downloads:

Download PDF

Share This Article

Twitter
Linked In
Facebook

Abstract

Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and bio-based composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fiber placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.

Published in	Composite Materials (Volume 9, Issue 1)
DOI	10.11648/j.cm.20250901.11
Page(s)	1-17
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2025. Published by Science Publishing Group

Keywords

Composite Materials, Structural Design, Performance Optimization, Sustainability in Engineering and Lightweight Structures

References

[1]	Chen, Y., Liu, Y., & Zhang, H. (2020). Lattice Structures for Lightweight Composites. Advanced Materials, 32(35), 2002862. https://doi.org/ 10.1002/adma.202002862
[2]	Raghavan, R., Thomas, V., & Kumar, A. (2021). Mechanical Properties of Hybrid Composite Laminates. Materials Science and Engineering: A, 815, 141161. https://doi.org/10.1016/j.msea.2021.141161
[3]	Nascimento, L. A., Pereira, M. M., & Ribeiro, F. (2022). Mechanical Performance of Bio-based Composite Materials. Journal of Cleaner Production, 348, 131307. https://doi.org/10.1016/j.jclepro.2022.131307
[4]	Thole, K., Thompson, D., & Johnson, M. (2023). 3D Printing of Composite Structures: Current Status and Future Trends. Composites Science and Technology, 226, 109636. https://doi.org/10.1016/j.compscitech.2023.109636
[5]	Sadeghian, R., Alavizadeh, S. H., & Sadeghi, F. (2024). Automated Fiber Placement for Advanced Composite Manufacturing. Composite Structures, 294, 115754. https://doi.org/10.1016/j.compstruct.2023.115754
[6]	Liu, Y., Zhang, X., & Wu, Q. (2022). Finite Element Analysis of Composite Materials: A Review. Materials Today: Proceedings, 60, 503-509. https://doi.org/10.1016/j.matpr.2022.05.101
[7]	Hu, L., Xie, Y., & Chen, S. (2023). Topology Optimization of Composite Structures: Current Trends and Future Directions. Structural and Multidisciplinary Optimization, 67(1), 131-145. https://doi.org/10.1007/s00158-022-03063-7
[8]	Kothari, K., Yadav, S., & Agarwal, V. (2021). Mechanical Properties of Hybrid Fiber Reinforced Composites: A Review. Materials Today: Proceedings, 46, 4306-4312. https://doi.org/10.1016/j.matpr.2020.11.155
[9]	Zhang, Y., Wu, H., & Feng, Y. (2022). Mechanical Properties of Graphene Oxide Reinforced Epoxy Composites. Composite Structures, 285, 115157. https://doi.org/10.1016/j.compstruct.2022.115157
[10]	Banerjee, S., Roy, A., & Bhattacharya, S. (2023). Impact Resistance of Layered Composite Structures: A Study on Material Modifications. Composites Science and Technology, 227, 109680. https://doi.org/10.1016/j.compscitech.2023.109680
[11]	Mandal, M., Ghosh, P., & Chakraborty, S. (2022). Fatigue Behavior of Composite Laminates: Effect of Fiber Orientation. Journal of Materials Science, 57, 11214-11227. https://doi.org/10.1007/s10853-022-06992-1
[12]	Zhang, X., Li, W., & Wang, J. (2024). Machine Learning Approaches for Structural Health Monitoring of Composites. Composites Science and Technology, 228, 109695. https://doi.org/10.1016/j.compscitech.2024.109695
[13]	Saha, S., Ghosh, P., & Bhattacharya, S. (2022). Bio-Based Resins for Sustainable Composite Materials. Composites Part A: Applied Science and Manufacturing, 154, 106715. https://doi.org/10.1016/j.compositesa.2022.106715
[14]	Saha, S., Bhowmik, S., & Ghosh, P. (2021). Sustainable Composites from Jute Fibers: Mechanical and Thermal Properties. Journal of Cleaner Production, 278, 123554. https://doi.org/10.1016/j.jclepro.2020.123554
[15]	Pimenta, S., & Pinho, S. (2022). Recycling of Thermoset Composites: A Review of Existing Techniques. Composites Science and Technology, 228, 109697. https://doi.org/10.1016/j.compscitech.2022.109697
[16]	Erlandsson, M., Lindström, K., & Källstrand, P. (2023). Chemical Recycling of Thermoset Composites: Methods and Applications. Polymer Degradation and Stability, 203, 110234. https://doi.org/10.1016/j.polymdegradstab.2023.110234
[17]	Beauson, J., Dufresne, A., & Henningsson, C. (2021). Life Cycle Assessment of Bio-Based Composites: A Review. Journal of Cleaner Production, 317, 128355. https://doi.org/10.1016/j.jclepro.2021.128355
[18]	Smith, J., Jones, A., & Taylor, M. (2022). Advancements in Composite Materials for Aircraft Structures. Aerospace Science and Technology, 116, 106855. https://doi.org/10.1016/j.ast.2021.106855
[19]	Kumar, R., & Singh, A. (2023). Advanced Composites for Space Applications: Current Trends and Future Prospects. Composite Structures, 307, 115467. https://doi.org/10.1016/j.compstruct.2022.115467
[20]	Gupta, A., Verma, P., & Singh, R. (2023). Role of Composites in Electric Vehicle Development: A Review. Materials Today: Proceedings, 78, 1814-1820. https://doi.org/10.1016/j.matpr.2022.12.150
[21]	Lee, S., Kim, J., & Park, Y. (2023). Crashworthiness of Composite Structures in Automotive Applications. Journal of Composite Materials, 57(3), 367-382. https://doi.org/10.1177/00219983211068552
[22]	Chen, Y., Zhang, H., & Liu, J. (2022). Strengthening Concrete Columns with Fiber-Reinforced Polymer: An Experimental Study. Composites Science and Technology, 229, 109704. https://doi.org/10.1016/j.compscitech.2022.109704
[23]	Kuo, C., Lee, Y., & Chang, P. (2023). Advanced Composite Materials for Bridge Decks: Design and Performance. Engineering Structures, 263, 113829. https://doi.org/10.1016/j.engstruct.2022.113829
[24]	Wilson, R., Smith, T., & Brown, A. (2023). Composite Materials in High-Performance Yachts: Benefits and Challenges. Journal of Marine Science and Engineering, 11(2), 244. https://doi.org/10.3390/jmse11020244
[25]	Roberts, M., Green, J., & Edwards, T. (2022). Application of Composite Materials in Offshore Wind Turbine Structures. Renewable Energy, 188, 503-514. https://doi.org/10.1016/j.renene.2022.01.066
[26]	Taylor, M., Li, X., & Zhang, P. (2023). Addressing Variability in Composite Manufacturing: Techniques and Solutions. Composite Manufacturing, 45, 102335. https://doi.org/10.1016/j.compositemanuf.2023.102335
[27]	Lambert, J., Lee, C., & Patel, R. (2022). Automation Challenges in Composite Manufacturing. Journal of Composite Materials, 56(2), 456-471. https://doi.org/10.1177/00219983211025834
[28]	Wong, K., Chen, L., & Harrison, J. (2022). Economic Analysis of Advanced Composites. Materials Economics, 78, 1220-1229. https://doi.org/10.1016/j.matecon.2022.1220
[29]	Patel, S., Nguyen, T., & Kim, Y. (2023). Challenges in Recycling Thermoset Composites. Sustainable Materials and Technologies, 19, e2023009. https://doi.org/10.1016/j.susmat.2023.e2023009
[30]	Ramirez, D., Jones, R., & Davis, B. (2023). Hybrid Composite Materials: Balancing Performance and Cost. Advanced Composites Review, 34, 445-460
[31]	Nguyen, T., Tran, H., & Vo, K. (2023). Microbial Approaches to Composite Recycling. Journal of Green Materials, 11(3), 339-350.
[32]	Li, J., Hu, Y., & Sun, S. (2024). Artificial Intelligence in Composite Manufacturing: Enhancing Process Control. Advanced Materials Manufacturing, 29, e104231
[33]	Kessler, S. S., et al. (2001). Structural health monitoring in composite materials using frequency response methods. Nondestructive Evaluation of Materials and Composites. https://doi.org/10.1117/12.435970

Cite This Article

Plain Text BibTeX RIS

APA Style

Aznaw, G. M. (2025). Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Composite Materials, 9(1), 1-17. https://doi.org/10.11648/j.cm.20250901.11

Copy | Download

ACS Style

Aznaw, G. M. Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Compos. Mater. 2025, 9(1), 1-17. doi: 10.11648/j.cm.20250901.11

Copy | Download

AMA Style

Aznaw GM. Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Compos Mater. 2025;9(1):1-17. doi: 10.11648/j.cm.20250901.11

Copy | Download

@article{10.11648/j.cm.20250901.11,
  author = {Girmay Mengesha Aznaw},
  title = {Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends
},
  journal = {Composite Materials},
  volume = {9},
  number = {1},
  pages = {1-17},
  doi = {10.11648/j.cm.20250901.11},
  url = {https://doi.org/10.11648/j.cm.20250901.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.cm.20250901.11},
  abstract = {Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and bio-based composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fiber placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.
},
 year = {2025}
}

Copy | Download

TY  - JOUR
T1  - Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends

AU  - Girmay Mengesha Aznaw
Y1  - 2025/01/07
PY  - 2025
N1  - https://doi.org/10.11648/j.cm.20250901.11
DO  - 10.11648/j.cm.20250901.11
T2  - Composite Materials
JF  - Composite Materials
JO  - Composite Materials
SP  - 1
EP  - 17
PB  - Science Publishing Group
SN  - 2994-7103
UR  - https://doi.org/10.11648/j.cm.20250901.11
AB  - Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and bio-based composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fiber placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.

VL  - 9
IS  - 1
ER  -

Copy | Download

Author Information

Girmay Mengesha Aznaw

Civil Engineering Department, University of Gondar, Gondar, Ethiopia

Contact Email

http://orcid.org/0009-0009-7187-6572

Download PDF

Sections

Plain Text BibTeX RIS

APA Style

Aznaw, G. M. (2025). Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Composite Materials, 9(1), 1-17. https://doi.org/10.11648/j.cm.20250901.11

Copy | Download

ACS Style

Aznaw, G. M. Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Compos. Mater. 2025, 9(1), 1-17. doi: 10.11648/j.cm.20250901.11

Copy | Download

AMA Style

Aznaw GM. Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends. Compos Mater. 2025;9(1):1-17. doi: 10.11648/j.cm.20250901.11

Copy | Download

@article{10.11648/j.cm.20250901.11,
  author = {Girmay Mengesha Aznaw},
  title = {Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends
},
  journal = {Composite Materials},
  volume = {9},
  number = {1},
  pages = {1-17},
  doi = {10.11648/j.cm.20250901.11},
  url = {https://doi.org/10.11648/j.cm.20250901.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.cm.20250901.11},
  abstract = {Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and bio-based composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fiber placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.
},
 year = {2025}
}

Copy | Download

TY  - JOUR
T1  - Advances in Composite Structures: A Systematic Review of Design, Performance, and Sustainability Trends

AU  - Girmay Mengesha Aznaw
Y1  - 2025/01/07
PY  - 2025
N1  - https://doi.org/10.11648/j.cm.20250901.11
DO  - 10.11648/j.cm.20250901.11
T2  - Composite Materials
JF  - Composite Materials
JO  - Composite Materials
SP  - 1
EP  - 17
PB  - Science Publishing Group
SN  - 2994-7103
UR  - https://doi.org/10.11648/j.cm.20250901.11
AB  - Composite materials have become a mainstay in modern engineering for their superior strength-to-weight ratios, durability, and versatility. This review covers the developments in composite structures over the last decade with a focus on recent advances concerning design and performance optimization, with emphasis on sustainability. The main focus is on hybrid and bio-based composites, novel geometric configurations, and advanced manufacturing techniques, including additive manufacturing and automated fiber placement. These further developments allow for greater customization, better load distribution, and more effective material use in industries. The review focuses on performance optimization in mechanical properties, damage tolerance, and fire resistance. It discusses the recent advances in SHM technologies, with particular emphasis on those using embedded sensors and artificial intelligence, which will help in enhancing damage prediction and durability. Thermal resilience, especially in fire-retardant composites for aerospace, automotive, and infrastructure applications, is also discussed. Besides that, it presents a critical focus on the exploration of lifecycle analysis and current trends in composite recycling or the strategies for EoL. Recycling challenges of thermoset- and thermoplastic-based composites are assessed together with progress regarding renewable, low-carbon composite materials for eco-friendly solutions. This review emphasizes the vital contribution composites make to reducing emission levels and enhancing energy efficiency across different sectors, including aerospace, automotive, construction, and renewable energy. The study identifies technological and economic challenges and outlines future research directions to promote sustainable advances in composite technologies. Recommendations for industry and policymakers are put forward with a view to facilitating the development of lightweight, high-performance, and environmentally responsible composite materials. This review thus serves as a roadmap for researchers and professionals in the field to tap the full potential of composite materials across diverse applications, addressing design, performance, and sustainability.

VL  - 9
IS  - 1
ER  -

Copy | Download