The iSurface project focuses on reducing failure in composite materials through state-of-the-art data acquisition, production flow analysis, and decision support tools. Z Prime leverages its expertise in digitalisation and AI-driven manufacturing to optimise monitoring and production processes, ensuring enhanced structural integrity and reliability of composite materials.

Challenges

Composite materials are prone to complex failure mechanisms, making failure prediction challenging. Damage from low-velocity impacts can lead to barely visible impact damage (BVID), which is hard to detect and significantly reduces the reliability of the structure. Over-conservative safety factors during design stages often lead to under-utilisation of the material.

The Project

iSurface aims to integrate structural health monitoring (SHM) technologies to provide real-time indications of the health state of composite structures. Technologies such as fibre optic sensors (FOS), fibre Bragg gratings (FBG), strain gauges, acoustic emissions, and piezoelectric transducers are employed for embedded sensing within composites.

The project also explores innovative contributions, including enTex Fibre Technology for enhancing epoxy resin systems, iTex Fibres for creating electrically conductive fibres, and smart materials capable of sensing and monitoring structural health. The building block (BB) approach facilitates meticulous development and testing, promoting weight reduction and sustainable aviation.

Z Prime’s Contributions

Z Prime develops and deploys a Data Acquisition (iDaQ) system capable of extracting reliable signals from smart materials such as nanomaterials like carbon nanotubes and graphene. Advanced analytics and AI provide structural health monitoring indications based on signals from the sensor matrix. The integration of these technologies ensures real-time monitoring, enabling early detection of damage and optimisation of maintenance processes.

Benefits

• • Enhanced Structural Integrity: Improves the fracture resistance of composite materials and allows continuous health monitoring.

• • Maintenance Optimisation: Optimises maintenance processes, reducing sudden failures and prolonging the lifespan of components.

• • Weight Reduction: Promotes sustainable aviation by reducing component weights and associated carbon emissions.

• • Real-Time Monitoring: Provides real-time structural health monitoring, ensuring timely interventions and improved reliability.

• • Innovation: Introduces cutting-edge smart materials and monitoring technologies, setting new standards in composite material applications.

Conclusion

The iSurface project offers a groundbreaking approach to enhancing the reliability and performance of composite materials. By integrating advanced structural health monitoring technologies and AI-driven analytics, iSurface addresses critical challenges in failure prediction and maintenance optimisation. Z Prime’s contributions ensure the success of this innovative project, demonstrating its potential to transform the use of composite materials in various industries, particularly aviation.