In this work, a blend of PEO, polysulfone (PSF), and lithium bis(trifluoromethanesulfonyl)imide (LiTFSi) was prepared at different PEO–PSf weight ratios (70-30, 80-20, and 90-10) and ethylene oxide to lithium (EO/Li) ratios (16/1, 20/1, 30/1, and 50/1). The samples were characterised using FT-IR, DSC, and XRD. Young’s modulus and tensile strength were evaluated at room temperature with micro-tensile testing. The ionic conductivity was measured between 5 °C and 45 °C through electrochemical impedance spectroscopy (EIS). The samples with a ratio of PEO and PSf equal to 70-30 and EO/Li ratio equal to 16/1 have the highest conductivity (1.91 × 10⁻⁴ S/cm) at 25 °C, while the PEO–PSf 80-20 EO/Li = 50/1 have the highest averaged Young’s modulus of about 1.5 GPa at 25 °C. The configuration with a good balance between electrical and mechanical properties is the PEO–PSf 70-30 EO/Li = 30/1, which has a conductivity of 1.17 × 10⁻⁴ S/cm and a Young’s modulus of 800 MPa, both measured at 25 °C. It was also found that increasing the EO/Li ratio to 16/1 dramatically affects the mechanical properties of the samples with them showing extreme embrittlement.

Ultrahigh temperature ceramics (UHTCs) were analyzed for their suitability in hypersonic flight conditions using balanced heat equations, transport equation, and finite element modeling technique. Mathematical model was derived on the assumption that the induced porosity follows linear and parabolic solutions of Laplace equation and applied external load mimicking hypersonic conditions with critical heat flux ranging between 7 and 44 MW/m². Simulations were carried out with four different UHTCs combinations and the results outlined a temperature rise exceeding 4700°C with deformation observed on the fixed area and where the heat flux was generated. The influence of porosity had a greater impact on the performance of the material as it led to a reduction in deformation compared to dense samples. Porous UHTCs exhibited a good thermal shock resistance owing to the release of thermal stresses through pores, which also enhanced the thermal insulation of the structure.

Carbon-fibre-supported cathodes are components of multifunctional energy-storage composites, but their manufacture requires coating routes capable of depositing electrochemically active material directly onto fibrous substrates with controllable loading and process consistency. This work investigates the electrophoretic deposition (EPD) of LiFePO₄/carbon-black/PVP composite cathodes onto carbon-fibre tow from an acetone-iodine suspension. Deposited areal mass was characterised across a 30–40 V and 5–10 min process window using three replicate depositions per condition. Mean coating loading ranged from 0.83 mg cm⁻² at 30 V/5 min to 4.82 mg cm⁻² at 40 V/10 min, while run-to-run variability was substantially greater at 40 V (52–61% coefficient of variation) than at 30 V (19–27%). Scanning electron microscopy showed successful particulate coating extending into the visible depth of the carbon-fibre tow without obvious large cracks or delamination at the examined magnification, while qualitative EDS mapping showed co-localised Fe, P, and O signals and a distributed N signal consistent with the PVP-containing coating. Electrochemical performance was demonstrated in a Li half-cell and in full-cell configurations employing graphite and carbon-fibre negative electrodes, illustrating that the EPD-manufactured cathode is electrochemically active, although further optimisation is required to improve the accessible performance. Overall, the study establishes a direct EPD route for manufacturing electrochemically functional, particle-coated carbon-fibre electrodes and identifies process consistency and cell integration as key considerations for their further development in multifunctional structural-battery architectures.