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Interfacing the IoT in composite manufacturing: An overview

  • Palanirajan Gowtham , Moses Jayasheela , Chinnaswamy Sivamani and Devarajan Balaji EMAIL logo
Published/Copyright: June 3, 2024
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REVIEWS ON ADVANCED MATERIALS SCIENCE
From the journal REVIEWS ON ADVANCED MATERIALS SCIENCE Volume 63 Issue 1

Abstract

It is a well-known fact that many sophisticated works consume a lot of human resources, leading to the need to find effective alternative. The manufacturing industry demands a lot of human resources, with around half of the global working population participating in this sector. Challenges such as sudden conflicts in the data, disasters, and loss of productivity are encountered by the manufacturing industries and can be overcome by monitoring machine performance data and automatically configuring the machines according to changing needs. This emphasizes the importance of the Internet of Things (IoT) in addressing niche areas of manufacturing. IoT is a buzzword heard everywhere around the globe. Implementing this technology makes most of the work more accessible than other conventional methods. This has created a lot of research interest on this topic. Among many manufacturing sectors, polymer composite material manufacturing is one of the most demanding. This review article purely focuses on polymer composite manufacturing and its allied processes. The consolidation of data is based on the influence of IoT on the extraction of fibers and manufacturing of polymer composite material using novel techniques, quality assessment of manufactured polymer composite material, challenges faced in exploring the use of IoT, and future scope. It can be stated from the survey that various researchers have minimally explored the incorporation of IoT, but its future looks very promising in terms of producing high-quality products at less time and lower cost by integrating this technique with conventional methods.

Keywords: IoT; composite manufacturing; additive manufacturing; quality

1 Introduction

Composite material is a material that combines the characteristics of two or more constituent elements [1]. In the end, the composites are stronger and lighter than the original material. Because of their numerous benefits and one-of-a-kind characteristics, composites have found widespread use across countless companies, with the worldwide composites economy estimated to rise $113.2 billion through 2022 [2]. Fiber-reinforced polymer (FRP) composite materials have been used in marine, aerospace, construction, as well as automotive industries, and nowadays 50% of the Boeing 787 airplane material content is composites [3]. In addition, Airbus expects a rise in carbon fiber supply of about 20,000 tonnes by 2020 [4]. FRP composites, notwithstanding their major benefits, are vulnerable to complex deficiencies during production, assembly, or wear and tear in service [5,6]. Deformations, de-bonding, delamination, and fiber breakage are the most common causes of in-service defects [7,8]. These flaws can result in permanent failure if they go unnoticed. As these deficiencies must be identified and the threshold restrictions determined to avoid such malfunctions, it is essential to do so [9,10]. The Federal Aviation Administration recognized the significance of a serious damage-specified tolerance inside its aircraft accreditation directives [11].

In addition, an in situ structural health monitoring (SHM) framework could indeed be used to diagnose as well as evaluate damage. To consistently diagnose and supervise the wellness of structures, the SHM system combines sophisticated sensing devices with post-processing methodologies [12,13,14,15]. However, it is hard to adopt SHM because of the extra weight and the cost of the equipment. When an aircraft has an SHM system installed, the highest landing weight would then increase, resulting in a decrease in operational cargo. The reduced cargo capacity reduces the number of people, which in turn reduces income [16]. Lightweight sensors with high identification limits seem to be preferable to ensure the practical implementation of SHM methodologies. Even though nondestructive testing (NDT) and SHM seem to be essentially numerous strategies, recent advancements in smart sensors and post-processing methodologies have made these contrasts less distinct [17,18]. To guarantee that NDT and SHM techniques can be seamlessly integrated for functional composite material applications, it is important to understand recent developments across NDT&E and in SHM techniques for critical damage categorization [19,20].

The Internet of Things (IoT) is an emerging technology that connects humans, machines, and materials through a common artificial intelligence platform. This technology oversees the data collection, data analysis, and decision-making regarding the process parameters involved in the production of various commodities [21,22]. Composite materials are the state-of-the-art materials that are the replacement for monolithic materials. Their quality solely depends on the raw materials used for manufacturing them and the method of manufacturing. To directly control the quality of the composite material, the involvement of IoT can be readily considered [23,24,25]. The entire survey reveals there is scope for digital technology in manufacturing, not only in health monitoring but also in other diverse areas such as the production of composites and data analysis for quality of manufacturing. In the following sections, we will discuss composite manufacturing and its quality assessment with the aid of IoT.

2 Extrudable FDM-based composite

A few works addressed a versatile material additive manufacturing (AM) technique comprising using an extruding nozzle that can move together across one or more axes while simultaneously dispensing one or many filaments. In this method, the filament is encased inside or through an extrudate fabricated by the nozzle. When the filament is delivered, it is principally coaxial well with an extrudable substance, resulting in an encapsulation. The filament is a conductive thermoplastic polymer, semiconductor, ceramic, coaxial cable, conductor, conductive polymer, optical fiber, magnetic material, fiber, tube, synthetic or natural thread, metal, or conductive powder. One or more filaments are wound into coils, formed into blocks, cylinders or other shapes to form various actuators, sensors, thermal management structures (e.g., using wire and/or a composite containing metal or boron nitride particles), chokes, switches, resistors, supercapacitors, fuses, inductors, capacitors, transformers, antennae (e.g., patch, fractal), variable-resistance resistors, external connecting pads, batteries, temperature sensors, pressure sensors, force sensors, capacitor plates, heat sinks, solenoids, cores and armatures for electromagnetic devices, heat conduction structures, or power supplies [26,27,28]. Another aspect of some studies focused on a versatile material AM technique comprising a first extruder for extruding an extrudable material; a filament, fiber, or wire dispenser that extrudes one or more filaments, in which the extrudate from the nozzle is encased in the extruded filament. For example, the filament is fabricated nearly coaxially only using a thermoplastic substance in various configurations. The filament is produced nominally by the coaxial extrusion of the thermoplastic substance [29,30].

2.1 Fiber-encapsulated AM

Fiber-encapsulated AM (hereinafter mentioned as FEAM; previously termed as 3D polymer + wire printing, or called 3dPWP) technique, system, and apparatus proposed in this work deliver a versatile material AM technique that can produce workable electromechanical devices by using a polymer along with a wire. More generally, the polymer may be another nonpolymeric material such as a ceramic, whereas wire may be a tube, a solidifying liquid, or another element, fiber, or filament of any composition. The term “polymer” encompasses all constituents extrudable through a nozzle and solidified by UV curing, thermal curing, evaporation, cooling, and so on. Similarly, the term “wire” includes a wire (e.g., metal wire) as well as any fiber and or filament including polymer fiber, carbon fiber, small-diameter tubing, glass fiber, and all other constituents and edifices possessing a filament or fiber-like shape [31,32]. These constituents may be monofilament or hold many strands, occasionally impregnated along with detained together with the help of resin similar to pre-preg used in composite production. FEAM significantly encompasses AM to enable the automated fabrication of multifunctional components, devices, and multi-material structures, including inductors, fuses, actuators, sensors, transformers, resistors, thermal management structures switches, antennae, embedded 3D circuitry, and capacitors, among other elements [33,34].

The co-deposition of fiber and combined resultant substance is the foundation of the FEAM process, which encapsulates the fiber while jointly depositing it. This feature alone allows for a wide range of products to be created. In addition, the FEAM process has additional capabilities that make it more versatile, such as stopping and starting a fiber (e.g., using a nozzle as described later), forming junctions between fibers that allow electric currents (or in some representations electro-optic signals) to flow from one fiber to another, linking fibers structurally so that stresses can be transferred from one fiber to another. The homogeneous manufacturing of perfectly functioning products and parts in the absence of the requirement for assembly could have a significant impact on the future of FEAM. Electronic components are now a reality because of monolithic fabrication. It is not just electrical components that can profit from monolithic fabrication; mechanical components can also be considered, leading to cost reduction and enhancing dependability and quality [35,36,37].

Materials such as nickel, copper, aluminum, silver, gold and silver-plated solder, and conductive composites are incorporated into a framework or device that is built section by section in a 3D printer by the FEAM method. The process is a one-step way of building up a structure or device layer by layer in 3D printing. On the one hand, it allows for the simultaneous deposition of metal and polymerization; on the other hand, it allows for the simultaneous deposition of metal and/or ferromagnetic wire. FEAM can do both. When it comes to designing robotic constructions with integrated electromechanical components, the capability to precisely place these three materials (and possibly others) opens up a world of possibilities [38,39]. Additive manufacture of 3D objects using conductive polymers, composites, polymers, and wires is described as a nonlinear and non-3D printing system and apparatus. There is a wide range of applications for these manufactured items, which include robotics, missile batteries, medical equipment, electronic goods, and various other businesses. They are reasonably versatile in that they include circuits, motors, and detectors. FEAM can be used to make devices that include sensors, antennas, integrated circuits that provide computing and storage, and also cells or energy recovery components (e.g., mechanical, electrostatic, capacitance, thermodynamic). In some cases, these sensors could be able to investigate their consumption record and structural rigidity, alerting users to the need for maintenance and providing other condition-monitoring data. IoT-enabled devices are conceivable, as shown in Figures 1 and 2 [40,41,42].

Figure 1 Schematic representation of segmenting and feeding a fiber composite [42].
Figure 1

Schematic representation of segmenting and feeding a fiber composite [42].

Figure 2 Schematic representation of an isometric cross-sectional view of an FEAM printing head [42].
Figure 2

Schematic representation of an isometric cross-sectional view of an FEAM printing head [42].

2.2 Fluid-based AM technique

Wire, fiber, or fluid conduit is partially enclosed within the matrix material in an extruded product that forms at least part of a layer. Although the extrudate’s longitudinal axis may be parallel to the primary (i.e., longitudinal) plane of the fiber in certain cases, the fiber could be arranged in any orientation relative to the extruded product in other cases. If the extrudate allows it, the fibers could be twisted or arranged in numerous ways. The dielectric matrix and a long-axis metal cable are approximately similar to the die-extruded materials. A fiber and a matrix material are deposited together, resulting in a fiber wrapped in a matrix. In some embodiments, a fiber enclosed in a grid and comprising at least a part of a layer is coupled to other fibers in the same or a different layer wirelessly, hydraulically, or both. A conductive matrix encapsulates a metallic wire and connects it to additional metal cables in an identical or a separate level. At a minimum, a part of a layer is made up of metallic filaments that are electronically linked to each other through the conductivity matrix, which is made up of polymer and nanoparticles of conductive material. An electrically conductive polymer matrix contains semiconducting particles at a sufficient density to ensure that pollutants from the piezoelectric medium do not significantly reduce conductance, and the accumulation of piezoelectric medium by particulate reinforcement does not impair conductivity [43,44,45].

Various methods such as joining, melting, annealing, ultrasound or thermosonic gluing, squeezing, wrapping, force connection, and reciprocal tangling are used to attach metal prongs. As long as the matrix phase has not yet solidified, the primary axis of the fiber is largely parallel to the extrudate’s axis, which allows for the monolithic fabrication of actuators, sensors, and wires while still contained in an originally liquid matrix material. Using a layer-over-layer AM method that incorporates multi-material, multifunctional layer-by-layer 3D circuitry that includes controllers, detectors, temperature control components, valves, converters, explosives, semiconductors, capacitance, inductive loads, and transmitters can be created. An enclosed metallic wire is soft and tempered in some circumstances, while in others, it has a circular broad spectrum [46,47]. The structure of an insulated metallic wire can be square based on the implementation. A spindle or other fiber storage device is rotated to offset the torsion caused by the deposition of a matrix and a fiber along a curved path. Co-deposition of a matrix and fiber over a curved path is performed regularly and radially to prevent twisting induced by the formation. For filament dispensing, the deposition head includes a least a single stream path for the metal matrix and at least one pipette. Variations in dielectric and conductive substances can both be included in the lamination necks at a minimum single flow path [48,49].

If moving through the fluid flow in any way, the microvascular in the deposition tip will dislodge and expel water from the fluid flow entirely. For instance, a deposition head may have a clamp that secures filament in place, and the capillary it is attached to is used to trigger the clamp. Vibration is being used to dispense or feed thread from a lamination device. Anchoring the filament in cemented matrix material, and afterwards pulling it off the deposition head, is the technique being used to feed variations strands [50,51]. Deposition heads use two or more rollers that touch the thread and move it via a capillary considerably larger in size than the filament’s exterior size to distribute or supply filaments. To put it simply, mechanical fatigue causes the filaments of variation to become brittle and break. It is necessary to eliminate matrix material from the filament when it exits a funnel or other wrapping so that it does not get encrusted with metal matrix. Laser treatment, burning, manual peeling, and plasma etching are used to remove the matrix material from a filament. Vascular height and/or filament feed rate are used to regulate fiber orientation within the extruded product all along deposition (e.g., vertical) axis. In some representations, fiber stance is governed in a closed-loop manner by sensing the filament position inside the extrudate and adjusting accordingly [52,53].

Capillary rotational angle and/or printer speed can be used to control filament position within a bent extruded product inside the layer planes (e.g., horizontal). Paths that comprise enclosed filament are preferred over those that do not contain filament and are ranked less. Pick-and-place or other techniques are being used to incorporate discrete parts into the completed item during the fabrication method. To maintain at least a few of the solid supports in the final product, gadget, element, system, product, or assembly, a detachable and advantageously soluble support material is provided, and at least some of the solid support is substantially contained in the matrix material. Some heat flux constructions use polypropylene and conductive particles as part of their conductive matrix to create integrated elements such as resistors with variable resistance, force sensors, temperature sensors, armatures, and cores for electromagnetic devices and capacitor plates for heating elements. Every one of these elements contains voids filled with fluid and may even be interlinked in many variants [54,55,56].

Gentle robots are an important application of some of the disclosures. It is common for traditional robotic systems to be made up of rigid components with rotating joints and limited actuators that can only move in one direction. Several technological and operational demands are enabling the growth of novel soft robotic systems. Soft robots may be better suited than hard ones to operate safely and productively with and in close vicinity to people because of their inherent compliance. Rigid robots have found it difficult to reliably grab and manipulate fragile, flexible, and irregular things (such as tools or apples on a tree) without damaging them; soft robots, on the other hand, provide an extra organic and possibly simpler response. It is possible that a soft robot, rather than a rigid one, could be used for rescue operation or soldier assistance because of its ability to crawl through small spaces [57,58]. The pulsatile movement of a caterpillar is one example of biomimetic locomotion that soft robots can use to navigate narrow passageways and uneven terrain. Soft robots can be more resilient, lighter, cheaper, and louder to handle than tough ones. It is also possible to incorporate high-resolution visual/tactile sensors into the skin of a soft robot, such as the GelSight substance, that has microscopic particles incorporated into its surface (GelSight Incorporation, Waltham, MA) [59,60].

Soft robots have a high number of variables, and many actuators can be impracticable, expensive, and bulky to construct and integrate using discrete parts of broad-area touch sensing. This is a major challenge for soft robots. Robotic limbs and bodies will need to have “embedded sensors and devices in natural fibers for robot bodies” over the next decade. The disclosure of a previously unheard-of capacity to print robots on their own enables automated, custom, quick, low-cost manufacture of whole, working robotics and robots’ components, including application-specific robots. When integrated circuits, memory, optoelectronic components, and radio frequency identification components are included in robotics systems in the form of micro-electromechanical system components, they can provide even more capability [61,62]. Other fields of application include strongly proficient, lifelike prosthetics; minimally invasive surgical instruments, microchannel gadgets with constructed pumps, high-temperature components mixers, and filters, which may incorporate fibers, optical fiber spacecraft, and electrode materials (i.e., for polyacrylamide gel); tailoring portable and bendable gadgets with integrated sensing devices and communication; and microchannel gadgets with constructed impellers and heaters. According to the description of the invention of this study, an innovative packaging approach can free electronic goods from the rigorous, horizontal restriction of printed circuits and offer new 3D screen sizes in which the item and loop become one. This approach removes various layers of traditional packaging, reducing size, weight, and cost while increasing the reliability of these product lines. Other fibrous elements, including fluid conduits and optical fibers, can be included in polymer structures manufactured according to the discovery [63,64]. All the above discussion underscores the importance of integrating IoT for the manufacturing of composite materials in various applications. Besides, the use of IoT has extended to the quality assessment of manufactured composite materials, which is comprehensively discussed in the forthcoming section.

3 Quality assessment for polymer composites using IoT

This article is related to the polymer composite materials manufacturing systems, methods, and apparatuses, specifically addressing automated quality checks for manufactured composite materials. A primary aspect involves an automated inspection system for monitoring a manufacturing process. This system comprises a core platform to connect various systems or subsystems via one or more interfaces and a sensor system coupled with the core platform to monitor the characteristics of a composite article being manufactured. The core platform is configured to receive a first measurement of one or more characteristics of a composite article from the sensor system while forming the composite article, receive data regarding a second measurement of one or more characteristics from the sensor system after curing the composite article, and generate an alert in response to detection of a defect in the composite article based on the first or second measurement [65,66].

The system further comprises a state manager operatively coupled with the core platform to determine a defect associated with one or more characteristics. The state manager is configured to determine whether a first defect exists in the composite article based on the first measurement. It is also configured to determine whether a second defect exists in the composite article based on the second measurement. Additionally, it is configured to identify a value corresponding to one or more characteristics associated with the defect based on the first or second measurement and calculate a score representing the degree of the defect of the manufactured article based on the identified value. The core platform is further configured to receive data regarding a third measurement of one or more characteristics after performing a trim operation on the composite article, determine whether a third defect exists in the composite article based on the third measurement, and generate an alert in response to a determination that a third defect exists in the composite article. The system further comprises a human–machine interface (HMI) operatively coupled with the core platform to provide an interface between an operator and the system. The core platform is configured to transmit the alert to the HMI, the alert comprising one of an audible or visual alert [67,68,69].

The system further comprises an actuation system operatively coupled with the core platform to implement the manufacturing process based on instruction from the core platform, wherein the core platform transmits the alert and information regarding the first or second defect to the actuation system to adjust an operating value of a manufacturing process of the system. The operating value comprises the speeds of the manufacturing process, the temperature of the curing stage, and the position of the composite article. The sensor system is operatively coupled with one or more of a noncontact ultrasound sensor, a laser sensor, an impedance sensor, an infrared sensor, or a heat sensor. The sensor system monitors one or more characteristics by two or more sensors of the sensor system to determine the first or second defect in the composite material. In certain aspects, the characteristic comprises a density, temperature, chemical composition, and thickness associated with the composite article [70,71,72].

A method of determining the integrity of a composite article comprises measuring, by a sensor, a first characteristic corresponding to the integrity of a composite article while forming the composite article; measuring, by the sensor, a second characteristic corresponding to the integrity of the composite article after curing the composite article; identifying, at a core platform, a defect based on the characteristic; and generating an alert in response to a determination that a defect exists in the composite article based on the first or second characteristic. The method further comprises determining, by the core platform, a defect value associated with the first or second characteristic, comparing the defect value to a plurality of defect values, and designating the manufactured article as containing a defect based on the comparison [73,74]. Besides, identifying by the core platform, a stage at which the defect appears; and adjusting an operating value of a manufacturing process based on the identification. The operating value comprises the speed of the manufacturing process, the temperature of the curing stage, and the position of the composite article. The density, temperature, chemical composition, and thickness associated with the composite article are also measured. Additionally, the alert is transmitted to an HMI operatively coupled with the core platform. The alert comprises video or audio identifying the defect [75,76].

With the advent of the IoT, whereby computing devices are embedded into everyday objects, the capability of sensing, processing, and communicating task-to-task details has become ubiquitous. To ensure continuous improvement in lean manufacturing, development should focus on issues of data analytics. For example, a computing architecture and infrastructure capable of communicating with a plurality of information sources (e.g., sensors, databases, interfaces, etc.) and/or analyzing data (e.g., firmware, hardware, software, algorithms, etc.) is desirable, such that all data can be compiled into a centralized server and/or data storage [77,78,79]. Further, given the proliferation of cheap, accurate sensors, the amount of data to parse to obtain meaningful information requires thoughtful consideration. Therefore, there is great potential to use sensors to obtain data from a variety of processes; however, significant hurdles remain before a complete solution is achieved [80,81].

Computing architecture and infrastructure capable of parsing large amounts of data to obtain meaningful information in the context of a variety of systems, for example, the state of an aircraft, the actions of a pilot within that state, and others, has been researched and developed over the years. Hardware and software architecture have been developed to benefit manufacturing technologies. As an example, a system can be configured to use cameras, a core computer containing core operating principles, and an HMI (e.g., a tablet or other computing device) to accept commands and/or share information with an operator [82,83]. In this manner, data can be digitized, such that the manufacturing process checklist can be configured to check for defects (e.g., FOD) on composite manufactured articles. It is further considered that the principles and/or systems described herein will have wide applicability for data capture and analytics to perform continuous improvement, leading to increasing automation. Ultimately, the necessity of a manual inspection by a Level 3 NDT technician may be eliminated through the methods and systems described herein, as shown in Figures 3 and 4 [84,85].

Figure 3 Schematic representation of flow of information data between subsystems. Adapted by a permission from [85].
Figure 3

Schematic representation of flow of information data between subsystems. Adapted by a permission from [85].

Figure 4 Schematic representation of an example layup process and elements of a laser-implemented inspection system. Adapted with a permission from [85].
Figure 4

Schematic representation of an example layup process and elements of a laser-implemented inspection system. Adapted with a permission from [85].

Table 1 consolidates how IoT is used in the manufacturing of composite materials along with the way it enhances the manufacturing process. In other way, the composite materials are being used in the sensors, which increase the efficiency of the IoT process. It helps the stakeholders to choose the specific type of requirement for a particular composite manufacturing process. Along with that, specific applications can also be identified, which would make it easy for researchers to work with versatile purposes.

Table 1

IoT versus polymer composite material

S. No Description Purpose Ref.
1 Perovskite material Enabling IoT [86]
2 Carbon nano-tubes Enabling IoT [87]
3 Reinforced composite Manufacturing [88]
4 Composite software Reduce the manufacturing cycle [89]
5 Adaptive apps and platforms Produce as well as to certify [90]
6 Sensors in the testing zone Image capturing, transfer [91]
7 Optimization in production Manufacturing and patent protection [92]
8 Production Reduces cost, waste, and downtime [93]
9 Electronic components Enabling IoT [94]
10 Through sensor Information transfer [95]
11 Diagnosis autonomously Health monitoring [96]
12 Real-time diagnosis Uncertainty assessment [97]
13 UAV blades Composite layups [98]
14 Patterning for conductivity Enabling IoT [99]
15 Manufacturing Load prediction [100]
16 NDT Defects assessment [101]
17 Manufacturing Improve the reliability [101]
18 Proper transmission of current Enabling IoT [102]
19 Production Mechanism saving [103]
20 Efficiency in conversion Bending strength analysis [104]
21 Production Realization [105]
22 Smartphone Monitoring the motion [106]
23 Manufacturing Integrating devices smoothly [107]
24 Aircraft vibration Power harvesting for sensors [108]
25 Assessing conductive polymers Enhance production [109]
26 Smart manufacturing Info sharing [110]
27 Two-phase material Develop dynamic sensor [111]
28 Manufacturing Trainer kit designing [112]
29 Production Enhancing the process [113]
30 Cellulose nano-fibril Enhance the conductivity [114]
31 Image processing with sensor Assessing state of drying [115]
32 Production Quality assessment [116]
33 Improve the sensor Estimate dynamic data [117]
34 Supermolecular polymers Modulating network percolation [118]
35 Composite physical chemistry Teaching the experiments [119]
36 Failure data analysis Leverage NDT data [120]
37 Halide Perovskite nano-generator Real-time data gathering [121]
38 Coconut shell helmet Strength analysis [122]
39 Manufacturing Process assessment [123]
40 Nano-fibers Pressure sensor [124]
41 Cellulose nano-fiber Data analysis [125]
42 Flexible antenna Reconfigurable [126]

4 Challenges and future scope

Implementation of IoT in full-scale for the manufacturing of polymer composites and quality assessment depends on various factors such as the cost of the process including raw materials and systems, the capability of the manufacturing and testing system to be digitized, availability of the data regarding the composition of the raw materials, and the data regarding the materials and manufacturing systems. Some predominant reasons of composite materials are unable to be adopted in product development are highlighted in Table 2.

Table 2

Barriers to adopting composites [127]

S. No. Constraints Description
1 Cost Finances involved in research and development as well as equipment cost to manufacture and testing is high
2 Capability Need to provide training for the task force, in turn which demands expertise and proper resources
3 Materials data Discrepancies in the standard define data for the materials are unavailable
4 Intellectual property IP owned by many stakeholders for smaller portions wherein it requires integration, therein I can be achieved only by collaboration
5 Material systems While migrating from one material to other new material involves lot of changes in the existing system, which in turn involves huge cost

The scope of polymer composites is always a tailor-made option owing to its pros and cons. A clear direction is important to overcome the constraints it possesses. Table 3 reveals how the barriers can be broken.

Table 3

Scope of IoT in polymer composite manufacturing [128]

S. No. Capabilities Description
1 Design and analysis The advanced technologies enable to test the materials with various digital techniques, leading to enhance the capabilities of composite manufacturing
2 Processes The growth in digital equipment provides a path to enhance the process like automation in composite manufacturing
3 Materials science Technological growth paves a path to the synthesis of hybrid materials
4 Technology enablers Digital world opens a forum to thought about the unconventional manufacturing of weird materials

5 Summary and conclusions

The survey reveals that composite manufacturing can be enhanced by the IoT in terms of quality and optimization of the raw materials. The primary sectors that use the IoT in composite manufacturing are communication, aerospace, and testing of polymer composites. In the early stage of adaptation of IoT in polymer composite manufacturing, its implementation is very limited. It is believed by experts that continuous progress in the field of IoT-interfaced polymer composite manufacturing requires a few more factors revealing the durability of the composite materials in various environmental factors such as the washing of fibers, high-temperature behavior, and flexural characteristics. There is a need for exploration of new production methods for polymer composite material to enhance the curing process efficiency, thereby improving the efficiency of the polymer composite manufacturing process. As a result, it has a wider scope to grow in the automation of composite manufacturing. It has been revealed that the barriers mentioned in adopting composite materials completely depend on advanced technological growth. Therefore, the incorporation of IoT is crucial for the development of better future composite products, as it can address the above-mentioned constraints. Materialists, technologists, and researchers in the field of composite materials for diverse applications can consider the utilization and full-scale implementation of IoT techniques for composite manufacturing to produce better-quality composite materials.

Acknowledgments:

The authors sincerely thank the Centre for Research and Development, KPR Institute of Engineering and Technology for providing necessary facilities to complete this review article.

  1. Funding information: The authors state no funding involved.

  2. Author contributions: Palanirajan Gowtham: conceptualisation and writing the article; Moses Jayasheela: conceiving and supervision; Chinnaswamy Sivamani: content revision and supervision; Devarajan Balaji: writing the article. All authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Conflict of interest: The authors state no conflict of interest.

  4. Data availability statement: Data sharing is not applicable to this article as no datasets were generated or analyzed during the current study.

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Received: 2023-07-19
Revised: 2024-03-01
Accepted: 2024-04-23
Published Online: 2024-06-03

© 2024 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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  12. Revolutionizing energy harvesting: A comprehensive review of thermoelectric devices
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  37. Development of a new damping ratio prediction model for recycled aggregate concrete: Incorporating modified admixtures and carbonation effects
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https://doi.org/10.1515/rams-2024-0026
Keywords for this article
IoT; composite manufacturing; additive manufacturing; quality
Creative Commons
BY 4.0

Articles in the same Issue

  1. Review Articles
  2. Effect of superplasticizer in geopolymer and alkali-activated cement mortar/concrete: A review
  3. Experimenting the influence of corncob ash on the mechanical strength of slag-based geopolymer concrete
  4. Powder metallurgy processing of high entropy alloys: Bibliometric analysis and systematic review
  5. Exploring the potential of agricultural waste as an additive in ultra-high-performance concrete for sustainable construction: A comprehensive review
  6. A review on partial substitution of nanosilica in concrete
  7. Foam concrete for lightweight construction applications: A comprehensive review of the research development and material characteristics
  8. Modification of PEEK for implants: Strategies to improve mechanical, antibacterial, and osteogenic properties
  9. Interfacing the IoT in composite manufacturing: An overview
  10. Advances in processing and ablation properties of carbon fiber reinforced ultra-high temperature ceramic composites
  11. Advancing auxetic materials: Emerging development and innovative applications
  12. Revolutionizing energy harvesting: A comprehensive review of thermoelectric devices
  13. Exploring polyetheretherketone in dental implants and abutments: A focus on biomechanics and finite element methods
  14. Smart technologies and textiles and their potential use and application in the care and support of elderly individuals: A systematic review
  15. Reinforcement mechanisms and current research status of silicon carbide whisker-reinforced composites: A comprehensive review
  16. Innovative eco-friendly bio-composites: A comprehensive review of the fabrication, characterization, and applications
  17. Review on geopolymer concrete incorporating Alccofine-1203
  18. Advancements in surface treatments for aluminum alloys in sports equipment
  19. Ionic liquid-modified carbon-based fillers and their polymer composites – A Raman spectroscopy analysis
  20. Emerging boron nitride nanosheets: A review on synthesis, corrosion resistance coatings, and their impacts on the environment and health
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  26. Study on dynamic response of cushion layer-reinforced concrete slab under rockfall impact based on smoothed particle hydrodynamics and finite-element method coupling
  27. Study on the mechanical properties and microstructure of recycled brick aggregate concrete with waste fiber
  28. Multiscale characterization of the UV aging resistance and mechanism of light stabilizer-modified asphalt
  29. Characterization of sandwich materials – Nomex-Aramid carbon fiber performances under mechanical loadings: Nonlinear FE and convergence studies
  30. Effect of grain boundary segregation and oxygen vacancy annihilation on aging resistance of cobalt oxide-doped 3Y-TZP ceramics for biomedical applications
  31. Mechanical damage mechanism investigation on CFRP strengthened recycled red brick concrete
  32. Finite element analysis of deterioration of axial compression behavior of corroded steel-reinforced concrete middle-length columns
  33. Grinding force model for ultrasonic assisted grinding of γ-TiAl intermetallic compounds and experimental validation
  34. Enhancement of hardness and wear strength of pure Cu and Cu–TiO2 composites via a friction stir process while maintaining electrical resistivity
  35. Effect of sand–precursor ratio on mechanical properties and durability of geopolymer mortar with manufactured sand
  36. Research on the strength prediction for pervious concrete based on design porosity and water-to-cement ratio
  37. Development of a new damping ratio prediction model for recycled aggregate concrete: Incorporating modified admixtures and carbonation effects
  38. Exploring the viability of AI-aided genetic algorithms in estimating the crack repair rate of self-healing concrete
  39. Modification of methacrylate bone cement with eugenol – A new material with antibacterial properties
  40. Numerical investigations on constitutive model parameters of HRB400 and HTRB600 steel bars based on tensile and fatigue tests
  41. Research progress on Fe3+-activated near-infrared phosphor
  42. Discrete element simulation study on effects of grain preferred orientation on micro-cracking and macro-mechanical behavior of crystalline rocks
  43. Ultrasonic resonance evaluation method for deep interfacial debonding defects of multilayer adhesive bonded materials
  44. Effect of impurity components in titanium gypsum on the setting time and mechanical properties of gypsum-slag cementitious materials
  45. Bending energy absorption performance of composite fender piles with different winding angles
  46. Theoretical study of the effect of orientations and fibre volume on the thermal insulation capability of reinforced polymer composites
  47. Synthesis and characterization of a novel ternary magnetic composite for the enhanced adsorption capacity to remove organic dyes
  48. Couple effects of multi-impact damage and CAI capability on NCF composites
  49. Mechanical testing and engineering applicability analysis of SAP concrete used in buffer layer design for tunnels in active fault zones
  50. Investigating the rheological characteristics of alkali-activated concrete using contemporary artificial intelligence approaches
  51. Integrating micro- and nanowaste glass with waste foundry sand in ultra-high-performance concrete to enhance material performance and sustainability
  52. Effect of water immersion on shear strength of epoxy adhesive filled with graphene nanoplatelets
  53. Impact of carbon content on the phase structure and mechanical properties of TiBCN coatings via direct current magnetron sputtering
  54. Investigating the anti-aging properties of asphalt modified with polyphosphoric acid and tire pyrolysis oil
  55. Biomedical and therapeutic potential of marine-derived Pseudomonas sp. strain AHG22 exopolysaccharide: A novel bioactive microbial metabolite
  56. Effect of basalt fiber length on the behavior of natural hydraulic lime-based mortars
  57. Optimizing the performance of TPCB/SCA composite-modified asphalt using improved response surface methodology
  58. Compressive strength of waste-derived cementitious composites using machine learning
  59. Melting phenomenon of thermally stratified MHD Powell–Eyring nanofluid with variable porosity past a stretching Riga plate
  60. Development and characterization of a coaxial strain-sensing cable integrated steel strand for wide-range stress monitoring
  61. Compressive and tensile strength estimation of sustainable geopolymer concrete using contemporary boosting ensemble techniques
  62. Customized 3D printed porous titanium scaffolds with nanotubes loading antibacterial drugs for bone tissue engineering
  63. Facile design of PTFE-kaolin-based ternary nanocomposite as a hydrophobic and high corrosion-barrier coating
  64. Effects of C and heat treatment on microstructure, mechanical, and tribo-corrosion properties of VAlTiMoSi high-entropy alloy coating
  65. Study on the damage mechanism and evolution model of preloaded sandstone subjected to freezing–thawing action based on the NMR technology
  66. Promoting low carbon construction using alkali-activated materials: A modeling study for strength prediction and feature interaction
  67. Entropy generation analysis of MHD convection flow of hybrid nanofluid in a wavy enclosure with heat generation and thermal radiation
  68. Friction stir welding of dissimilar Al–Mg alloys for aerospace applications: Prospects and future potential
  69. Fe nanoparticle-functionalized ordered mesoporous carbon with tailored mesostructures and their applications in magnetic removal of Ag(i)
  70. Study on physical and mechanical properties of complex-phase conductive fiber cementitious materials
  71. Evaluating the strength loss and the effectiveness of glass and eggshell powder for cement mortar under acidic conditions
  72. Effect of fly ash on properties and hydration of calcium sulphoaluminate cement-based materials with high water content
  73. Analyzing the efficacy of waste marble and glass powder for the compressive strength of self-compacting concrete using machine learning strategies
  74. Experimental study on municipal solid waste incineration ash micro-powder as concrete admixture
  75. Parameter optimization for ultrasonic-assisted grinding of γ-TiAl intermetallics: A gray relational analysis approach with surface integrity evaluation
  76. Producing sustainable binding materials using marble waste blended with fly ash and rice husk ash for building materials
  77. Effect of steam curing system on compressive strength of recycled aggregate concrete
  78. A sawtooth constitutive model describing strain hardening and multiple cracking of ECC under uniaxial tension
  79. Predicting mechanical properties of sustainable green concrete using novel machine learning: Stacking and gene expression programming
  80. Toward sustainability: Integrating experimental study and data-driven modeling for eco-friendly paver blocks containing plastic waste
  81. A numerical analysis of the rotational flow of a hybrid nanofluid past a unidirectional extending surface with velocity and thermal slip conditions
  82. A magnetohydrodynamic flow of a water-based hybrid nanofluid past a convectively heated rotating disk surface: A passive control of nanoparticles
  83. Prediction of flexural strength of concrete with eggshell and glass powders: Advanced cutting-edge approach for sustainable materials
  84. Efficacy of sustainable cementitious materials on concrete porosity for enhancing the durability of building materials
  85. Phase and microstructural characterization of swat soapstone (Mg3Si4O10(OH)2)
  86. Effect of waste crab shell powder on matrix asphalt
  87. Improving effect and mechanism on service performance of asphalt binder modified by PW polymer
  88. Influence of pH on the synthesis of carbon spheres and the application of carbon sphere-based solid catalysts in esterification
  89. Experimenting the compressive performance of low-carbon alkali-activated materials using advanced modeling techniques
  90. Thermogravimetric (TG/DTG) characterization of cold-pressed oil blends and Saccharomyces cerevisiae-based microcapsules obtained with them
  91. Investigation of temperature effect on thermo-mechanical property of carbon fiber/PEEK composites
  92. Computational approaches for structural analysis of wood specimens
  93. Integrated structure–function design of 3D-printed porous polydimethylsiloxane for superhydrophobic engineering
  94. Exploring the impact of seashell powder and nano-silica on ultra-high-performance self-curing concrete: Insights into mechanical strength, durability, and high-temperature resilience
  95. Axial compression damage constitutive model and damage characteristics of fly ash/silica fume modified magnesium phosphate cement after being treated at different temperatures
  96. Integrating testing and modeling methods to examine the feasibility of blended waste materials for the compressive strength of rubberized mortar
  97. Special Issue on 3D and 4D Printing of Advanced Functional Materials - Part II
  98. Energy absorption of gradient triply periodic minimal surface structure manufactured by stereolithography
  99. Marine polymers in tissue bioprinting: Current achievements and challenges
  100. Quick insight into the dynamic dimensions of 4D printing in polymeric composite mechanics
  101. Recent advances in 4D printing of hydrogels
  102. Mechanically sustainable and primary recycled thermo-responsive ABS–PLA polymer composites for 4D printing applications: Fabrication and studies
  103. Special Issue on Materials and Technologies for Low-carbon Biomass Processing and Upgrading
  104. Low-carbon embodied alkali-activated materials for sustainable construction: A comparative study of single and ensemble learners
  105. Study on bending performance of prefabricated glulam-cross laminated timber composite floor
  106. Special Issue on Recent Advancement in Low-carbon Cement-based Materials - Part I
  107. Supplementary cementitious materials-based concrete porosity estimation using modeling approaches: A comparative study of GEP and MEP
  108. Modeling the strength parameters of agro waste-derived geopolymer concrete using advanced machine intelligence techniques
  109. Promoting the sustainable construction: A scientometric review on the utilization of waste glass in concrete
  110. Incorporating geranium plant waste into ultra-high performance concrete prepared with crumb rubber as fine aggregate in the presence of polypropylene fibers
  111. Investigation of nano-basic oxygen furnace slag and nano-banded iron formation on properties of high-performance geopolymer concrete
  112. Effect of incorporating ultrafine palm oil fuel ash on the resistance to corrosion of steel bars embedded in high-strength green concrete
  113. Influence of nanomaterials on properties and durability of ultra-high-performance geopolymer concrete
  114. Influence of palm oil ash and palm oil clinker on the properties of lightweight concrete
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