Composites represent a cutting-edge frontier material compared to traditional metals and alloys based on steel, aluminum, 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 progresses, 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.
Segregated Into Four Categories
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 fibre reinforcement. In a composite, the fibre, 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. Fibre properties are determined by the fibre manufacturing process, type of material used in fibre manufacturing and the ingredients and coating chemistries used in the process.
Freedom from Past Programmes
The present article deals with fibres used in composite and high-performance applications, where Bharat should make serious concentrated efforts with due representation from industry, academia and research institutes. It should be freed from the old legacies/histories and burden of the past programmes which are running over decades, entangled in red tapism.
The fibre used in composite applications are called reinforcements. Bharat needs its own strategic reinforcement fibre. 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 programmes including multidisciplinary teams is the need of the hour.
This article seeks 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 Aatmanirbhar, otherwise this fibre development has been going on since the last 40 years in various national institutions with huge funding from the 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 not a single commercial product is available in Bharat.
The strategic fibre essentially are carbon fibres of PAN as well as Pitch. Basalt fibres, being abundant natural resources, are available in Bharat. Glass Fibre H-Glass, R-Glass, S2-Glass. Silica Glass, Quartz fibre Ballistic and composite application Para-Aramid fibre (Kevlar Equivalents) and Meta-Aramid Fibre (Nomex Types), HMHDPE and HMHDPP fibres are used in bullet-proofs and other aerospace applications.
We should think of a mission mode approach of development and manufacturing of the aforelisted strategic fibres. However, a separate plan for utilising natural fibres like jute, bamboo, banana, coir etc. can be made but the subject of strategic fibres and natural fibres should be dealt separately.
We are witnessing a 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 fibres – 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 fibres 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 fibres, 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 fibres from a multidisciplinary 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.
Holistic Approach Is Necessary
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, fibre, and weaving technology perspective plays an equally important role, as fibre 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 fibre 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.
In Sync with National Security
Beyond the technical aspects, a Bharat-centric strategic perspective is essential to align composite technology development with national security, defence, and space programme 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 fibre, resins, and intermediates will reduce dependency on imports and enhance technological sovereignty.
Association Is Crucial
Finally, none of this can be achieved without coordination and association among partners, 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 multidisciplinary approach, can we 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 fibres, 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 fibres through innovations in chemistry and material science.
A Bharat-centric strategic perspective is essential to align composite technology development with national security, defence, and space programme objectives
Textile – Fibre and Weaving Technology Perspective: Textile engineering plays a crucial role in the spinning of critical materials for production of fibres and the weaving techniques used to create composite materials. Research in this area involves developing advanced spinning and weaving technologies, improving fibre alignment and distribution, and optimising textile processes to ensure consistent quality and manufacturability of composite fibres. But 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 fibre 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 fibre 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 the fibre development programme.
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 fibres.
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 sectors. The tests and accreditation should also be linked with fibre 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.
Bharat can unlock opportunities for sustainable economic growth, environmental conservation, and technological innovation in the burgeoning field of composite materials
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 collaboration, 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 fibres and composite materials to drive innovation, economic growth, and sustainable development.
The prioritisation of key strategic fibres for indigenisation missions necessitates comprehensive case studies to devise effective implementation plans tailored to each fibre type. These case studies would encompass various topics relevant to the specific characteristics and applications of each fibre. For example, for carbon fibres derived from PAN and Pitch, the case study may focus on optimising production processes, enhancing fibre properties, and addressing supply chain challenges. On the other hand, for basalt fibres where the raw material is abundant in Bharat, the case study might explore opportunities for sustainable sourcing, improving manufacturing efficiency, and identifying novel applications. Similarly, case studies for glass fibres could delve into enhancing fibre compositions for specific industry needs at chemistry level, optimising manufacturing techniques at engineering level, and ensuring quality control measures. For aramid fibres like Kevlar equivalents, the case study may examine advancements in ballistic protection technologies, performance testing methodologies, and market penetration strategies. Additionally, case studies for HMHDPE and HMHDPP fibres might involve evaluating potential applications in diverse sectors, optimising material properties, and encouraging collaborations with key partners. By conducting such detailed case studies, partners can develop tailored strategies to promote the indigenous production, utilisation, and innovation of strategic fibres, thereby strengthening Bharat’s self-reliance and competitiveness in the global composite materials marketplace and crucial applications depending on this market.
Variants of Strategic Fibres
Carbon Fibres (PAN and Pitch): Carbon fibres derived from PAN and Pitch offer exceptional strength-to-weight ratios and high stiffness, making them ideal for applications where lightweight, high-performance materials are essential. Research efforts focus on optimising production processes and enhancing fibre properties to meet specific performance requirements. Most technologists know that there is a big range of fibres in this category, and we should select a few to consider for developmental industrialisation as per national priority. We know that M/s Reliance Industries and M/s Jindal Advance Materials have announced manufacturing of industrial grade fibres. It is not very clear about the grades both the companies are trying to manufacture. Countries should have some details of their project implementation plan as these are highly strategic fibres. Carbon fibre holds the highest priority among all fibre types and will therefore be discussed in detail as a representative case. Key Aspects of Studying these Cases
Basalt Fibre: Basalt rocks, which are raw materials for making fibres, are abundantly available in Bharat, offering a sustainable alternative to traditional reinforcement materials, particularly in the infrastructure industry. With exceptional mechanical properties, corrosion resistance, and thermal stability, they are ideal for various structural and high-temperature applications.
Glass Fibres (H-Glass, R-Glass, S2-Glass): Glass fibres come in various compositions, each tailored to specific performance characteristics. H-Glass fibres offer high strength and modulus, R-Glass fibres provide improved resistance to alkali and moisture, while S2-Glass fibres offer superior tensile strength and impact resistance. These fibres find applications in aerospace, automotive, construction, and marine industries.
Silica Glass and Quartz Fibre: Silica glass and quartz fibres exhibit exceptional thermal and chemical resistance, making them suitable for high-temperature and harsh- environment applications. These fibres are used in aerospace, defence, and electronics industries, where reliability and performance under extreme conditions are critical.
Aramid Fibres (Kevlar Equivalents): Aramid fibres, such as Kevlar equivalents, are renowned for their exceptional strength, abrasion resistance, and low weight. These fibres find widespread use in ballistic protection, aerospace, automotive, and sporting goods applications where high-performance composites are required to withstand extreme conditions.
HMHDPE and HMHDPP Fibres: High-modulus, high-density polyethylene (HMHDPE) and polypropylene (HMHDPP) fibres offer excellent mechanical properties, chemical resistance, and toughness. These fibres are utilised in various applications, including automotive components, marine structures, and protective equipment (bullet proofs), where lightweight, durable materials are essential.·
Natural Fibres: Bharat boasts a rich repository of natural fibres that hold immense potential for composite applications. Among these, jute, coir, banana and bamboo fibres stand out as promising candidates. Jute fibres, derived from the jute plant, offer impressive tensile strength and durability, making them suitable for reinforcing composites in various sectors such as automotive, construction, and packaging. Coir fibres, extracted from coconut husks, exhibit excellent resilience and moisture resistance, rendering them ideal for applications in marine environments and horticulture. Banana fibres, sourced from banana stems, possess remarkable flexibility and biodegradability, making them well-suited for eco-friendly composite products. Bamboo fibres, known for their exceptional strength-to-weight ratio and rapid growth rate, offer sustainable alternatives for structural reinforcement in construction and furniture industries. By exploring and harnessing the potential of these indigenous natural fibres, Bharat can unlock opportunities for sustainable economic growth, environmental conservation, and technological innovation in the burgeoning field of composite materials.
Super Speciality Fibres: A separate plan is essential for advancing research-oriented ceramic fibres such as Boron Nitride, Silicon Carbide, and Alumina, along with super specialty fibres like PBO (poly(p-phenylene-2,6-benzobisoxazole)), from a Bharatiya perspective. These fibres hold immense potential for high-end applications demanding exceptional mechanical, thermal, and chemical properties. The plan should prioritise intensive research and development efforts aimed at enhancing the properties and manufacturability of ceramic and specialty fibres. This includes investigating novel synthesis techniques, optimising fibre morphology, and exploring innovative coatings to improve performance and tailor properties to specific applications. Bharat’s plan should emphasise exploring diverse applications for these fibres across strategic sectors such as aerospace, defence, automotive, electronics, and renewable energy. Ceramic fibres, known for their high-temperature stability and corrosion resistance, can find applications in advanced thermal management systems, protective coatings, and electronic substrates. Similarly, PBO fibres, renowned for their exceptional strength and modulus, are well-suited for ballistic protection, aerospace components, and sporting goods. The plan should focus on leveraging Bharat’s indigenous resources and capabilities for material sourcing, processing, and manufacturing. This includes identifying locally available raw materials, establishing research collaborations with domestic industries and academic institutions and developing indigenous manufacturing technologies to ensure self-reliance and sustainability. To support research and innovation in ceramic and specialty fibres, Bharat needs to invest in state-of-the-art infrastructure and testing facilities. This includes setting up advanced laboratories for fibre characterisation, performance testing, and quality assurance, as well as providing access to cutting-edge equipment and instrumentation for research institutions and industry partners. The plan should prioritise skill development and capacity building initiatives to cultivate a talented workforce capable of driving innovation and technology transfer in the field of ceramic and specialty fibres. This includes establishing specialised training programmes, academic courses, and collaborative research projects to nurture talent and expertise in fibre science and engineering. Bharat’s plan should include strategies for commercialising research outcomes and penetrating global markets with high-value ceramic and specialty fibre-based products. This involves fostering industry-academia partnerships, supporting technology transfer and entrepreneurship initiatives, and promoting Bharat’s capabilities and expertise in fibre technology through international collaborations and trade missions. By implementing a comprehensive plan tailored to Bharat’s specific needs and strengths, the country can position itself as a leader in the development and utilisation of ceramic and specialty fibres, driving innovation, economic growth, and sustainable development in strategic sectors.
Case Study Points Fibre Categories
Raw Material Sources: Analyse the availability, characteristics, and suitability of Pitch and PAN as raw material sources for carbon fibre production, considering factors such as cost, quality, and environmental impact. Polymerisation Effectiveness: Evaluate the efficiency and performance of PAN polymerisation processes, benchmarking against global leaders in carbon fibre production to identify best practices and areas for improvement.
Bharatiya Mesophase-Pitch Precursor: Investigate the potential of Bharatiya mesophase- pitch precursors for carbon fibre manufacturing, assessing their properties and competitiveness compared to international counterparts.
Precursor Selection: Determine the optimal precursor for producing Standard Modulus (SM), Intermediate Modulus (IM), and Ultra-High Modulus (UHM) carbon fibres, considering factors such as precursor type, quantity requirements, and fibre modulus specifications across different yarn sizes (1k to 48k).
Precursor vs. Manufacturing/Mechanics and Application: Analyse the correlation between precursor properties, manufacturing techniques, mechanical performance, and application suitability of carbon fibres, identifying key factors influencing final product characteristics and market acceptance.
Spinning Technology: Explore advanced spinning technologies for precursor conversion into carbon fibres, assessing their efficiency, scalability, and potential for enhancing fibre quality and production yield.
Carbonisation Technology: Investigate carbonisation processes and technologies to optimise fibre conversion from precursor materials, focusing on achieving desired fibre properties, uniformity, and cost-effectiveness.
Sizing, Weaving, and Prepreg Technologies: Examine sizing methods, weaving techniques, and prepreg manufacturing processes for converting intermediate carbon fibres into composite materials, addressing challenges related to fibre-matrix adhesion, composite strength, and manufacturing efficiency. Testing and Accreditation: Establish comprehensive testing and accreditation protocols to ensure the quality, performance, and compliance of carbon fibre products with industry standards and regulatory requirements. Testing Facilities: Invest in state-of-the-art testing laboratories equipped with advanced equipment for characterising carbon fibre properties, including tensile strength, modulus, density, thermal conductivity, and electrical conductivity and endurance /NDT. Accreditation Bodies: Collaborate with accredited organisations or establish national accreditation bodies to certify carbon fibre products and manufacturing processes, ensuring adherence to international quality standards and regulations.
Skilled Personnel: Recruit and train qualified technicians and scientists and engineers with expertise in materials testing, quality control, and accreditation procedures to conduct thorough assessments and certifications. Research and Development: Allocate resources for ongoing research and development initiatives to advance testing methodologies, develop new testing standards, and address emerging challenges in carbon fibres characterisation and accreditation.
Industry Collaboration: Long-term partnerships with industry stakeholders, academic institutions, and government agencies to share resources, expertise, and best practices in testing and accreditation, promoting continuous improvement and innovation in carbon fibre manufacturing and quality assurance. Resources Required (also to consider establishing a Laboratory in PPP way) Bharatiya Aerospace Programme and Import Restrictions: Evaluate the future trajectory of Bharat’s aerospace industry and the potential impact of import restrictions on carbon fibre availability and domestic manufacturing capabilities, identifying strategies to enhance self-reliance and competitiveness in the sector.
Key aspects for studying Highly Strategic case of Basalt fibres
Market Analysis: Evaluate current and potential market demand for basalt fibres in Bharat across industries such as civil construction, automotive, and infrastructure. Raw Material Sourcing: Assess availability, quality, and sustainability of basalt deposits in Bharat for fibre production (which has been exported at a dirt low price at present). Production Process Optimisation: Investigate cost-effective and environmentally sustainable methods for extracting basalt fibres and refining manufacturing processes.
Product Development: Research and develop innovative applications and formulations for basalt fibres to meet industry-specific performance requirements including sizing and consistency.
Cost-Benefit Analysis: Compare the production costs of basalt fibres with traditional reinforcement materials to determine cost competitiveness and economic viability.
Quality Control: Implement stringent quality control measures to ensure consistent fibre quality and performance standards.
Supply Chain Management: Develop robust supply chain networks for raw materials, manufacturing equipment, and distribution channels to optimise efficiency and reliability. Regulatory Compliance: Navigate regulatory frameworks and compliance requirements governing fibre production, safety, and environmental standards.
Marketing and Branding: Strategise marketing campaigns to promote the benefits and applications of basalt fibres, targeting key stakeholders and decision-makers.
Partnership and Collaboration: Forge strategic partnerships with industry players, academic institutions, and government agencies to leverage expertise, resources, and funding for research and development initiatives.
Each of these strategic fibres plays a crucial role in advancing composite technology, offering unique properties and performance characteristics that enable innovation and efficiency across a wide range of industries. Case studies should be performed for each fibre type, considering the most relevant key aspects. This approach ensures a comprehensive analysis tailored to the specific characteristics of each fibre. Collaborative efforts between industry, academia, and research institutes are essential to optimise these fibre properties, develop advanced manufacturing processes, and accelerate the adoption of composites in various applications. However, our plan must be prioritised based on strategic requirements, ensuring alignment with the nation’s sovereignty and long-term needs.
Comments