Researchers at Seoul National University (SNU), South Korea, have developed a new method for manufacturing strong yet lightweight carbon fibre structures without the need for layered assembly or joints.
Carbon fibre composites are typically manufactured by stacking thin layers of material or assembling multiple components. Even newer approaches, such as 3D printing, rely on layer-by-layer fabrication.
The challenge is that these methods introduce weaknesses where layers or parts meet, and create internal boundaries that can disrupt load transfer.
To overcome this, SNU researchers explored whether they could build a structure by placing a single continuous fibre directly in three-dimensional space.
Their process begins with a temporary scaffold that defines nodal geometry. A long carbon fibre is then wound across these nodes, forming a spatial lattice network. Once the geometry is established, the structure is consolidated through resin impregnation, producing a solid composite.
As the fibre...