Structural materials, typically based on metal, have been gradually substituted by high-performance composites based on carbon fibers, embedded in a polymer matrix, due to their potential to provide lighter, stronger, and more durable solutions. In the last decades, the composites industry has witnessed a sustained growth, especially due to diffusion of these materials in key markets, such as the construction, wind energy, aeronautics, and automobile sectors. Carbon fibers are, by far, the most widely used fiber in high-performance applications. This important technology has huge potential for the future and it is expected to have a significant impact in the manufacturing industry within Europe and, therefore, coordination and strategic roadmapping actions are required. To lead a further drive to develop the potential of composites into new sectors, it is important to establish strategic roadmapping actions, including the development of business and cost models, supply chains implementation, and development, suitability for high volume markets and addressing technology management. Europe already has a vibrant and competitive composites industry that is supported by several research centers, but for its positioning in a forefront position in this technology, further challenges are still required to be addressed.

Carbon concrete polyacrylonitrile (PAN)/lignin-based carbon fiber (CF) composites are a new promising material class for the building industry. The replacement of the traditional heavy and corroding steel reinforcement by carbon fiber (CF)-based reinforcements offers many significant advantages: a higher protection of environmental resources because of lower CO₂ consumption during cement production, a longer lifecycle and thus, much less damage to structural components and a higher degree of design freedom because lightweight solutions can be realized. However, due to cost pressure in civil engineering, completely new process chains are required to manufacture CF-based reinforcement structures for concrete. This article describes the necessary process steps in order to develop CF reinforcement: (1) the production of cost-effective CF using novel carbon fiber lines, and (2) the fabrication of CF rebars with different geometry profiles. It was found that PAN/lignin-based CF is currently the promising material with the most promise to meet future market demands. However, significant research needs to be undertaken in order to improve the properties of lignin-based and PAN/lignin-based CF, respectively. The CF can be manufactured to CF-based rebars using different manufacturing technologies which are developed at a prototype level in this study.

Solid-state supercapacitors (SSCs) consist of porous carbon electrodes and gel-polymer electrolytes and are used in novel energy storage applications. The current study aims to simulate the impedance of SSCs using a clearly defined equivalent circuit (EC) model with the ultimate goal of improving their performance. To this end, a conventional mathematical and a physicochemical model were adapted. The impedance was measured by electrochemical impedance spectroscopy (EIS). An EC consisting of electrical elements was introduced for each modeling approach. The mathematical model was purely based on a best-fit method and utilized an EC with intuitive elements. In contrast, the physicochemical model was motivated by advanced theories and allowed meaningful associations with properties at the electrode, the electrolyte, and their interface. The physicochemical model showed a higher approximation ability (relative error of 3.7%) due to the interface impedance integration in a more complex circuit design. However, this model required more modeling and optimization effort. Moreover, the fitted parameters differed from the analytically calculated ones due to uncertainties in the SSC’s microscale configuration, which need further investigations. Nevertheless, the results show that the proposed physicochemical model is promising in simulating EIS data of SSCs with the additional advantage of utilizing well-reasoned property-based EC elements.

Structural supercapacitors (SSCs) are multifunctional energy storage composites (MESCs) that combine the mechanical properties of fiber-reinforced polymers and the electrochemical performance of supercapacitors to reduce the overall mass in lightweight applications with electrical energy consumption. These novel MESCs have huge potentials, and their properties have improved dramatically since their introduction in the early 2000’s. However, the current properties of SSCs are not sufficient for complete energy supply of electrically driven devices. To overcome this drawback, the aim of the current study is to identify key areas for enhancement of the multifunctional performance of SSCs. Critical modification paths for the SSC constituents are systematically analyzed. Special focus is given to the improvement of carbon fiber-based electrodes, the selection of structural electrolytes and the implementation of separators for the development of more efficient SSCs. Finally, current SSCs are compared in terms of their multifunctionality including material combinations and modifications.

Detailed knowledge of the local fiber orientation and the local fiber volume content within composite parts provides an opportunity to predict the structural behavior more reliably. Utilizing forming simulation methods of dry or pre-impregnated fabrics allows for predicting the local fiber orientation. Additionally, during the forming process, so-called draping effects like waviness, gapping or shear-induced transverse compression change the local fiber volume content. To reproduce and investigate such draping effects, different manufacturing tools have been developed in this work. The tools are used to create fabric samples with pre-defined deformation states, representing the different draping effects. The samples are evaluated regarding the resulting fiber volume content. The experimental results are compared with the predictions of an analytical solution and of a numerical solution based on draping simulation results. Furthermore, the interaction of the draping effects at arbitrary strain states is discussed regarding the resulting fiber volume content.