Carbon fibre for applications in aerospace: A review

The aerospace industry increasingly relies on advanced composite materials to enhance structural performance while reducing environmental impact. Among these materials, carbon fibre-reinforced polymers (CFRPs) have emerged as the dominant choice due to their exceptional strength-to-weight ratio, fatigue resistance, and thermal stability. This review aims to provide a comprehensive analysis of the development, properties, manufacturing techniques, and sustainability aspects of carbon fibre composites in aerospace applications. A systematic literature-based approach was employed to evaluate recent advancements in microstructural design, automated manufacturing, and recycling technologies. The findings reveal that carbon fibre composites achieve 30–50 % weight reduction and 20–25 % fuel savings compared to traditional aluminium and titanium alloys, while maintaining superior mechanical and thermal performance. Emerging AI-driven, digital twin-based manufacturing systems improve process reliability, reducing defect rates by up to 30 % and reducing production cycles by 25–35 %. Moreover, hybrid and nanoreinforced composites incorporating carbon nanotubes or graphene demonstrate 10–25 % improvements in interlaminar strength and damage tolerance. From a sustainability perspective, recycling methods such as pyrolysis and solvolysis enable the recovery of 90–95 % of carbon fibres with minimal property degradation, supporting circular economy goals. The novelty of this review lies in integrating materials science, digital manufacturing, and sustainability to establish a unified framework for next-generation aerospace composites. In conclusion, carbon fibre technology stands at the intersection of high performance, intelligent manufacturing, and environmental responsibility, driving the evolution toward lighter, stronger, and more innovative aerospace systems. • Carbon fibre cuts weight by 30–50 % and saves 20–25 % fuel in aircraft. • AI and digital twins cut defects 30 %, boost cycle efficiency 25–35 %. • Nanocomposites enhance strength, damage tolerance by up to 25 %. • Recycling recovers 90–95 % fibres with minimal degradation. • Integrates performance, smart manufacturing, and sustainability.