Comprehensive Review of Composite Materials: Classification, Manufacturing Methods, Mechanical Behavior, Failure Modes, and Emerging Applications

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 923 939
    By

    Ritesh Fegade,

  • Ramakant Chaudhari,

  • Rupendra Nehete,

  • Vithoba Tale,

  • Dnyaneshwar Mate,

  • Pandurang Chopade,

  • Sachin Yadav,

  • Somnath Kolgiri,

  1. Associate Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitribai Phule Pune University, Wagholi, Pune, Maharashtra, India
  2. Assistant Professor, Department of Mechanical Engineering, Padmashri Dr. V. B. Kolte College of Engineering, Malkapur, Maharshtra, India
  3. Professor, Department of Mechanical Engineering, SIES Graduate School of Technology, Nerul, Navi Mumbai, Maharshtra, India
  4. Associate Professor, Department of Mechanical Engineering, Rajarshi Shahu College of Engineering, Tathawade, Pune, Maharshtra, India
  5. Associate Professor, Department of Mechanical Engineering, Rajarshi Shahu College of Engineering, Tathawade, Pune, Maharshtra, India
  6. Assistant Professor, Department of Mechanical Engineering, Padmashri Dr. V. B. Kolte College of Engineering, Malkapur, Maharshtra, India
  7. Assistant Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitribai Phule Pune University, Wagholi, Pune, Maharshtra, India
  8. Associate Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitribai Phule Pune University, Wagholi, Pune, Maharashtra, India

Abstract

Composite materials have emerged as one of the most significant classes of engineered materials due to their ability to deliver high strength to weight ratios, enhanced durability, and tailored multifunctionality. Over the past two decades, rapid progress in polymer chemistry, advanced reinforcement architectures, additive manufacturing, and automated fabrication has expanded the applicability of composites across aerospace, automotive, biomedical, civil, and renewable energy sectors. This paper provides a comprehensive review of composite material classification, with emphasis on polymer, metal, and ceramic matrices, along with microscale and nanoscale reinforcements. A detailed comparison of conventional and advanced manufacturing methods including resin transfer molding, filament winding, vacuum assisted processes, automated fiber placement, and nano enabled fabrication is presented. The mechanical behavior of composites under tensile, flexural, impact, and fatigue loading is discussed alongside the critical failure mechanisms such as delamination, matrix cracking, interfacial debonding, and fiber pull out. The review also examines emerging trends, including multifunctional composites, self-healing systems, structural health monitoring enabled smart materials, and AI assisted design frameworks. By synthesizing recent developments and identifying current limitations, this paper highlights future research opportunities aimed at improving sustainability, recyclability, and high temperature performance in next generation composite systems.

Keywords: Composite materials, mechanical properties, epoxy matrix, sustainable materials, polymer.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Ritesh Fegade, Ramakant Chaudhari, Rupendra Nehete, Vithoba Tale, Dnyaneshwar Mate, Pandurang Chopade, Sachin Yadav, Somnath Kolgiri. Comprehensive Review of Composite Materials: Classification, Manufacturing Methods, Mechanical Behavior, Failure Modes, and Emerging Applications. Journal of Polymer & Composites. 2026; 14(01):923-939.
How to cite this URL:
Ritesh Fegade, Ramakant Chaudhari, Rupendra Nehete, Vithoba Tale, Dnyaneshwar Mate, Pandurang Chopade, Sachin Yadav, Somnath Kolgiri. Comprehensive Review of Composite Materials: Classification, Manufacturing Methods, Mechanical Behavior, Failure Modes, and Emerging Applications. Journal of Polymer & Composites. 2026; 14(01):923-939. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236661


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Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 25/11/2025
Accepted 19/12/2025
Published 07/02/2026
Publication Time 74 Days
158

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