Composites represent a cutting-edge frontier material compared to traditional metals and alloys based on steel, aluminium, iron, and titanium. Design and manufacturing experts are currently probing deeper into capabilities of composites, recognising their exceptional physical properties, particularly their lightweight nature, high strength and high temperature endurance. This characteristic makes composites highly appealing due to their unique blend of strength, stiffness, and durability, all while significantly reducing weight. As research and innovation in composite materials progress, they have the potential to revolutionise multiple sectors. From aerospace and automotive industries to civil construction and renewable energy, composites promise to enhance efficiency, performance, and sustainability on a transformative scale.
Composites are usually classified by the type of material used for the matrix. The four primary categories of composites are polymer matrix composites (PMCs), metal matrix composites (MMCs), ceramic matrix composites (CMCs), and carbon matrix composites (CMCs). The structural properties of composite materials are primarily derived from the fiber reinforcement. In a composite, the fiber, held in place by the matrix resin, contributes to tensile strength, enhancing performance properties in the final part, such as strength and stiffness, while minimising weight. Fiber properties are determined by the fiber manufacturing process, type of material used in fiber manufacturing and the ingredients and coating chemistries used in the process.
The present article deals with fibers used in composite and high-performance applications, where Bharat should make serious concentrated efforts with due representation from Industry, Academia and Research institutes and it should be freed from the old legacies/ histories and burden of the past programs which are running over decades, entangled in Red tapism.
The fibers used in composite applications are called reinforcements. Bharat needs its own strategic reinforcement fibers on high priority. The subject of reinforcement is multi-disciplinary in nature, it cannot be understood completely alone by a chemist, a chemical engineer, textile professional or a mechanical engineer or a material science professional, therefore chalking out several comprehensive techno commercial sustainable programs including multi-disciplinary teams is the need of the hour.
This article is targeted not only at technical professionals but also at policymakers and nationalist readers. It seeks out to highlight our dependence on strategically important products, urging for informed policymaking and implementation. This topic is as crucial as getting correct engines for our indigenous fighter aircraft LCA. Only the right approach will make us Atmanirbhar, otherwise this fiber development has been going on since last 40 years in various national institutions with huge funding from government without any commercial production entity being ready in Bharat. In the process of research many got awards, lots of scientific employment generated but till now single commercial product is not available in Bharat.
The strategic fibers essentially are Carbon Fibers of PAN as well as Pitch. Basalt Fiber being abundant natural resources available in Bharat, Glass fibers H-Glass, R-Glass, S2-Glass. Silica Glass, Quartz Fiber. Ballistic and composite application Para-Aramid fibers (Kevlar Equivalents) and Meta-Aramid Fibers (Nomex Types), HMHDPE and HMHDPP fibers used in bullet-proofs and other aerospace applications.
We should think of a mission mode approach of development and manufacturing of the afore listed strategic fibers. However, a separate plan for utilising natural fibers like Jute, Bamboo, Banana, Coir etc. can be made but the subject of strategic fibers and natural fibers should be dealt separately.
We are witness to the global conflict situation, it is a power struggle, and we also know the technology oriented mineral struggle of futuristic material is also an unspoken underlying major truth of all the wars. It is known that the ‘quartz sand’ mineral useful for processing quartz fiber is available in abundance in Gaza strip or ‘rare earths’ of Ukraine or Greenland or Canada cannot be put in oblivion when we talk about current conflicts. With the increasing need for high-performance materials, ceramic fibers such as Boron Nitride, Silicon Carbide, and Alumina will be essential for applications in aerospace thermal protection systems, hypersonic missile/ vehicle components, high-temperature structural parts including sixth or so spoken eighth generations fighter aircraft or advanced drones and nuclear insulations. Similarly, PBO-type super specialty fibers, known for their exceptional strength and thermal resistance, are crucial for ballistic armour, advanced aerospace composites, fire-resistant PPEs and deep-space structures. To meet future demands, a dedicated research plan should be developed to explore and optimise these materials for emerging high-performance applications.
To delve deeper into the topic, it is essential to explore composite fibers from a multi-disciplinary perspective. Meaningful industrial and applied development cannot occur without a comprehensive understanding of the subject’s various facets. This shift in perspective is crucial for moving beyond the traditional, mission-oriented approach to funding, where resources are allocated to a select group of so-called experts, often resulting in limited long-term benefits once the mission is concluded. This statement is not intended as criticism but rather as a call to prepare ourselves for the technological challenges that lie ahead— we can say the situation is the equivalent of a “technological pandemic” that could disrupt industries and Nations in the near future.
To navigate these challenges effectively, we must adopt a holistic thought process that considers multiple dimensions. From a material science and chemical perspective, understanding the chemistry and fundamental properties of composites is crucial to optimising performance. The textile, fiber, and weaving technology perspective plays an equally important role, as fiber architecture and textile processing significantly influence composite behaviour. Additionally, the structural and composite mechanics perspective is vital for analysing load-bearing capabilities, failure mechanisms, and durability in complex applications. Another key aspect is the composite matrix properties perspective, where the role of matrices is often underestimated despite their crucial influence on overall composite behaviour. This ties closely to the composite processing perspective, which encompasses advanced manufacturing techniques such as resin transfer moulding (RTM), automated fiber placement (AFP), pultrusion, and additive manufacturing. Equally important is the testing and accreditation perspective, as rigorous validation, compliance with global standards, and national accreditation ensure the reliability and consistency of composite materials in demanding applications.
Beyond the technical aspects, a Bharat-centric strategic perspective is essential to align composite technology development with national security, defence, and space program objectives. Simultaneously, a Bharat-specific commercial perspective is needed to encourage self-reliance in composites for sectors such as automotive, infrastructure, and renewable energy. Strengthening the raw material and manufacturing technology perspective is also critical, as developing indigenous capabilities for producing high-performance fibers, resins, and intermediates will reduce dependency on imports and enhance technological sovereignty.
Finally, none of this can be achieved without coordination and association among stakeholders, replacing outdated internal competition-driven models with a cooperative ecosystem. Research institutions, industries, and government agencies must work together to eliminate redundant efforts and maximise impact. Only by embracing this multi-disciplinary approach we can drive meaningful progress in composite materials technology, ensuring that we are prepared for the challenges and opportunities that lie ahead.
Material Science and Chemical perspective: This perspective focuses on understanding the chemical composition and structure of fibers, as well as the matrix materials used in composites. Research in this area aims to develop novel materials, optimise manufacturing processes, and enhance the performance characteristics of composite fibers through innovations in chemistry and material science.
Textile – Fiber and Weaving Technology perspective: Textile engineering plays a crucial role in the spinning of critical materials for production of fibers and the weaving techniques used to create composite materials. Research in this area involves developing advanced spinning and weaving technologies, improving fiber alignment and distribution, and optimising textile processes to ensure consistent quality and manufacturability of composite fibers. At the same time it should not be just left with textile industry alone, categorising it as Technical Textile.
Structural and Composite Mechanics perspective: This perspective focuses on understanding the mechanical behaviour of composite materials under various loading conditions. Researchers study factors such as fiber orientation, matrix properties, and interface interactions to predict and optimise the structural performance of composite components. Advanced modelling and simulation techniques are employed to analyse and design composite structures with enhanced strength, stiffness, and durability.
Composite Properties perspective: The properties of composite materials are influenced by both the fibers and the matrix materials. This perspective examines how different matrix materials affect the mechanical, thermal, and chemical properties of composites. Research in this area aims to develop matrices with tailored properties to enhance overall composite performance, including factors such as adhesion, toughness, and resistance to environmental degradation. This essentially needs to be part of fiber development program.
Composite Processing perspective: Composite processing encompasses a range of techniques used to manufacture composite materials, including moulding, filament winding, pultrusion etc. Research in this area focuses on optimising processing parameters, developing novel manufacturing techniques, and improving process efficiency and repeatability to reduce production costs and enhance the quality and scalability of composite fabrication is highly dependent on the quality of reinforcing fibers.
Testing and Accreditation perspective: Testing and accreditation are essential for ensuring the quality, reliability, and safety of composite materials and components. Research in this area involves developing standardised testing methods, establishing quality control procedures, and obtaining certifications to validate the performance of composite products. Advanced non-destructive testing techniques are also explored to assess the integrity and durability of composite structures. We can think of having expert testing and accreditation laboratories such as one for the aerospace sector in a private public partnership mode. Similarly, one can have for automotive or wind and civil engineering sector. The tests and accreditation should also be linked with fiber development.
Bharat Specific Strategic Approach: This perspective considers the unique challenges, opportunities, and priorities relevant to the Bharatiya context. Research/ Production in this area focuses on addressing strategic needs such as defence, infrastructure, and sustainable development, leveraging Bharat’s strengths in natural resources, manufacturing capabilities, and technological innovation to drive the growth and competitiveness of the composite industry.
Bharat Specific Commercial perspective: Commercialisation is crucial for translating research innovations into market-ready products and services. This perspective involves identifying market opportunities, developing business models, and adopting industry- academia partnerships to accelerate technology acceptance and market penetration. Research in this area also explores strategies for intellectual property protection, market positioning, and keeping an eye on global competitiveness in key sectors.
Raw Material and Manufacturing Technology Approach: This perspective examines the availability, accessibility, and sustainability of raw materials used in composite production, as well as advancements in manufacturing technologies. Research focuses on optimising material sourcing, reducing production costs, and minimising environmental impact through innovations in recycling, waste management, and sustainable manufacturing practices.
Coordination and Cooperation among different Teams: Effective coordination and cooperation among stakeholders are essential for maximising the impact and efficiency of composite research and development efforts. This perspective emphasises the importance of interdisciplinary association, knowledge sharing, and resources pooling to avoid duplication of efforts, adopt innovation, and accelerate technology transfer and adoption.
By addressing these perspectives comprehensively and nurturing association across disciplines and sectors, Bharat can harness the full potential of strategic fibers and composite materials to drive innovation, economic growth, and sustainable development.
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