Researchers at the National Institute of Technology (NIT), Rourkela, have successfully secured patent (Patent No. 596943) for their novel three-dimensional (3D) reinforced advanced composite manufacturing technology. The research team comprised Dr. Rajesh Kumar Prusty, Assistant Professor, Prof. Bankim Chandra Ray, Professor, and research scholar Mr. Parimal Jana of NIT Rourkela, in collaboration with Dr. Dinesh Kumar Rathore of MNIT Jaipur. The patented technology was developed at the FRP Composite Laboratory of the Department of Metallurgical and Materials Engineering, NIT Rourkela. According to the latest press release from NIT-R, this innovation addresses one of the major limitations of conventional FRP composites: their vulnerability to internal damage under heavy loading that can lead to cracks, delamination and structural failure over prolonged use.
The NIT team has developed a hybrid three-dimensional reinforced composite by integrating glass fibres with graphene nanoplatelets aligned through the thickness of the composite during manufacturing. As reported by Business Standard, this unique internal architecture enables the fibres, graphene nanoplatelets and epoxy matrix to work together more efficiently, resulting in a significantly tougher and more durable material capable of resisting crack propagation and structural failure. According to Rajesh Kumar Prusty, assistant professor at NIT Rourkela, this unique internal architecture enables the fibres, graphene nanoplatelets and epoxy matrix to work together more efficiently, resulting in a significantly tougher and more durable material capable of resisting crack propagation and structural failure. The distinguishing feature of the patented technology is its ability to align unmodified graphene nanoplatelets within glass fibre-reinforced epoxy composites using a simple and industry-compatible manufacturing process. Instead of requiring expensive or complex fabrication techniques, the researchers introduced only a minor modification to conventional composite manufacturing by applying a standard 50 Hz alternating-current electric field of 800 volts during the curing stage.
Laboratory tests conducted as per ASTM standards showed impressive performance gains: a 37% increase in tensile strength, a 30% improvement in flexural strength, a 63% rise in flexural modulus, a 26% improvement in tensile modulus, a 24% improvement in interlaminar shear strength, a 33% increase in Mode-I fracture toughness, a 53% increase in Mode-II fracture toughness, and a 55% higher storage modulus at 40 degrees Celsius. According to the researchers, this makes the process readily adaptable to existing industrial composite production systems without substantial changes in manufacturing infrastructure. The technology also recorded a 26% enhancement in tensile modulus, showing comprehensive improvement across multiple mechanical properties. As reported by Bhubaneswar News, FRP composites are used in commercial aircraft, defence platforms, space launch vehicles, high-speed rail systems, renewable energy infrastructure and hydrogen storage tanks because of their high strength-to-weight ratio, corrosion resistance and design flexibility, but their performance can deteriorate when subjected to prolonged or heavy mechanical loads.
The innovation is expected to improve the reliability and lifespan of lightweight structural components used in commercial aircraft, defence platforms, space launch vehicles, high-speed rail systems, wind energy installations and hydrogen storage infrastructure. As reported by Business Standard, FRP composites are widely regarded as advanced engineering materials because of their exceptional strength-to-weight ratio, high fatigue resistance, design flexibility and excellent corrosion resistance. These characteristics have made them indispensable in industries where reducing weight without compromising structural integrity is critical. According to Rajesh Kumar Prusty, assistant professor at NIT Rourkela, the technology has wide-ranging applications wherever lightweight yet damage-tolerant materials are essential, including aircraft panels, automotive crash structures, wind turbine blades, marine structures and pressure vessels. The technology also has potential applications in defence, marine engineering and hydrogen storage sectors. Highlighting its applications, Dr. Rajesh Kumar Prusty said the technology could be used in aircraft panels, automotive crash structures, wind turbine blades, pressure vessels, marine structures and other advanced engineering components requiring lightweight yet damage-tolerant materials.
According to Business Standard, the innovation could lower maintenance costs, improve energy efficiency and promote sustainable manufacturing by producing lighter yet more durable structural materials. Bankim Chandra Ray, professor at NIT Rourkela, stated that the technology has the potential to contribute significantly to India's Atmanirbhar Bharat mission by strengthening domestic capabilities in advanced materials manufacturing. The research team is now working on evaluating the material in larger structural components, assessing long-term environmental durability, and pursuing technology licensing and industry collaborations for commercial deployment. As reported by Bhubaneswar News, the innovation could reduce maintenance costs, improve energy efficiency and promote sustainable manufacturing while supporting India's Atmanirbhar Bharat mission in advanced materials.
