Electrically conductive nano scale polymeric fibres combined with advanced AI multi-sensor data enables real-time, predictive early warning of catastrophic failure from barely visible impact damage
[London: 25 February 2025] iSurface, a project led by Munro Technology, Z Prime, Axalp Technologies AG and researchers from Swiss university of applied sciences FHNW (Fachhochschule Nordwestschweiz), today unveiled a new intelligent composites material for Enhanced Robustness and Real-Time Structural Health Monitoring of aerospace structures. Its immediate impact is on early warning systems as well as the reduction in inspection-detection-evaluation time, frequency and human errors. iSurface unlocks significant savings in maintenance and upkeep costs whilst improving the reliability and performance of aircraft and wind turbines.
Composites are prone to damage by low velocity impacts that can cause hard to detect, barely visible impact damage (BVID). iSurface enables embedded early warning system significantly reduces risk of catastrophic failure of aviation parts such as wings’ leading edges, propeller blades and other structures close to the ground and subject to Foreign Object Debris (FOD) impact.
The new iSurface material is functionalised and has electric properties that not only strengthens composite structures but also generates clean, classifiable and interpretable signals. These sensed signals can declare the sum of energy and its location of the surface upon impact, bending and shearing events. The generated signals are linked to an advanced and novel material state AI-driven modelling diagnostics and prognostics.
Munro Technology is functionalising its novel fibre technology enTex to create electrically conductive nano scale polymeric fibres, iTex. Z-Prime brings its advanced AI expertise to support the development of the Structural Health Monitoring (SHM) platform, leveraging the electrical conductivity capabilities of iTex. Integration of iSurface into composite materials and its commercial application is led by Axalp Technologies AG, a Swiss-based company bringing interdisciplinary aerospace engineering services and engineering project execution. The result is a radically new approach to enhancing Structural Health and Reliability of composite materials used in critical aerospace structures.
“Integrated self-diagnosing Structural Health Analysis powered by AI technologies has the potential to revolutionise the design, manufacture and deployment of critical and damage prone components in the aerospace, turbine and high-tech automotive sectors,” said Dr Peyman Adl, Chief Operating Officer, Z Prime. “The embedding of safety factors into the predictive early warning of Structural Health Monitoring in real-time increases the trust for the use of modern, light and tough composite material into industries such as aviation. Together with Munro’s expertise in materials and fibre reinforced composites, we have invented a material that enables the aeronautical industry to reduce structure weight for more sustainable travel and transition from the current schedule-based practices to condition-based maintenance reducing both their cost and risk.”
“The failure of metallic structures is relatively well understood; however, the failure mechanisms in composite materials are more complicated making prediction and provision of cost-effective maintenance regimes challenging,” said Dr Ata Yoosefinejad, Munro Technology. “Modern composites/material with excellent stiffness-to-weight ratio lack self-diagnosing capabilities, are underutilised within the industry and remain conceptual. In collaboration with Z Prime, we can now use advanced material modelling with AI to leverage the electrical conductivity capabilities of this new intelligent composite and potentially transform how critical aircraft structures are designed, manufactured and maintained.”
iSurface is currently deployed in proof-of-concept structures for prototype/experimental aircraft. The industrialisation of certified solutions is expected in 2027-28.
iSurface will be showcasing a demonstrator package at JEC World 2025 in Paris (4-6 March 2025). iSurface will be present on the FHNW booth located on the Composites United Pavilion (Hall 6, stand P24). For more information on JEC World 2025, please visit https://www.jec-world.events
iSurface project partners
FHNW (Fachhochschule Nordwestschweiz) is the University of Allied Sciences and Arts Northwestern Switzerland. FHNW’s Institute of Polymer Engineering combines expertise in the fields of chemistry and analytics, process engineering and structural mechanics to creates sustainable, plastic-based product and processes innovations with a focus on high-performance polymers and composites. For more information, please visit: https://www.fhnw.ch/en/about-fhnw/schools/school-of-engineering/institutes/institute-of-polymer-engineering
Axalp Technologies AG is a Swiss-based company bringing interdisciplinary aerospace engineering services and engineering project execution to partner companies. Formed in 2020, the Axalp team builds on years of successful work together on fast-paced engineering development programs for unconventional aircraft. With a background heavily rooted in – but not restricted to – aerospace systems, Axalp offers a broad set of engineering skills and tools to tackle any complex engineering system. For more information, please visit: https://axalptech.com
Munro Technology Ltd, founded in 2007 in South West England, specialises in materials science, engineering, and energy absorption and crash worthiness of advanced composite materials. The company produces fracture toughness interleaf material enTex and is active in development of novel nanomaterials that serves industries, including automotive, motorsports, sports equipment, and aerospace. For more information, visit https://www.munrotechnology.com/
Z Prime Ltd specialises in AI-driven industrial optimisation and sustainability solutions. Headquartered in London, UK with offices in Munich, Germany and Dubai, the company combines a global team of AI, Industrial and Environmental experts and R&D partnerships with leading industry and academia including Brunel University London and Imperial College London. Z Prime is backed by Symax Group, an international investment company with a diverse portfolio of technology companies and specialist management expertise in helping innovative and advanced technology companies grow. For more information, please visit: https://zprime.ai
