“For five decades, CCM has not only advanced research but also trained generations of engineers who now lead in industry, government and academia,” added Suresh Advani, the Unidel Pierre S. du Pont Chair of Engineering and former associate director of CCM. “That combination of research excellence and workforce development sets us apart.”

CCM’s reputation for excellence is built on decades of discoveries that have improved how composites are designed and manufactured.

Improving processes

Composites are typically made by placing strong fibers into a mold and adding resin, which quickly gels and hardens to lock everything into shape. But if the fibers are not fully coated with resin, the material develops weak spots and cannot be used.

CCM researchers developed a computer simulation that maps where resin travels inside a closed mold containing dry fibers, helping manufacturers avoid dry spots and voids. Airbus and Boeing have applied the technology to make composite aircraft parts, and it can be adapted for many other uses.

Promoting sustainability

Many composites rely on nonrenewable resources, such as petroleum-based resins, and energy-intensive manufacturing processes. CCM has long pursued greener alternatives.

In the 1990s, the late Richard Wool, former CCM Director, partnered with John Deere to produce a composite hay bailer door using a resin based on soybean oil, proving that it is possible to make durable, high-performance composites using plant oils. Wool went on to become a leader in developing strong, high-performance materials from renewable ingredients like vegetable oils, flax and chicken feathers, for which he was honored with a Presidential Green Chemistry Challenge Award in 2013. Producing these materials requires less water and energy and yields less hazardous waste than petroleum-based processes.

That commitment to sustainable materials continues today. Pilla was honored with the 2021 Presidential Green Chemistry Challenge Award for developing the first nonisocyanate polyurethane foam, an innovation he achieved prior to joining UD. This foam replaces potentially cancer-causing diisocyanates with lignin, a natural polymer from pulp and paper waste, creating a recyclable, safer alternative.

More recently, CCM collaborated with Clemson University and Honda to design and create a lightweight door for the Acura MDX. With funding from the Department of Energy (DOE), the researchers created a door from thermoplastic composites, which are light and environmentally friendly. Because they could not change the door’s size or shape, they combined the inner panel and trim into a single piece. The result was a door 45% lighter than steel and fully recyclable. It exceeded expectations in crash tests, though it is still years away from hitting the market. 

In addition to its industry partnerships, CCM pioneers new composite technologies developed within its labs. One example is development of tailored universal feedstock for forming, or TuFF. This high-performance material can be produced inexpensively from recycled composite parts or scrap carbon fiber.

Lightweight and extremely strong, TuFF can be stamped into complex shapes, opening the door for automotive, aerospace, electronics and infrastructure applications. It also enables composites that are difficult for radar to detect, combining performance and stealth in a single material.

Advancing toward the future with AI

Looking ahead, CCM is integrating artificial intelligence into composites research. As part of a DOE Energy Frontier Research Center, UD is building an AI framework that seeks to flip the traditional discovery process: manufacturers could input their requirements, and AI would propose the material composition and manufacturing process. “This expedites the whole discovery process. Building that AI-driven framework for inverse design of composites is a big part of our future,” said Pilla.

CCM also plans to investigate ways to integrate active intelligence into composites. This goes a step beyond pre-programmed “smart” materials to composite materials that learn, respond and adapt in real time.

For a center built on collaboration and discovery, these next frontiers are a natural evolution of its pioneering spirit.

By prioritizing sustainability, advanced manufacturing and AI-powered design, CCM continues to push the boundaries of what composites can do. The next 50 years promise to continue the center’s long tradition of tackling complex challenges to shape the future of industries and everyday life.