Nearly all‐natural and synthetic composites derive their characteristic attributes from a hierarchical makeup. Engineered metamaterials exhibit properties not existing in natural composites by precise patterning, often periodically on size scales smaller than the wavelength of the phenomenon they influence. Lightweight fiber‐reinforced polymer composites, comprising stiff/strong fibers embedded within a continuous matrix, offer a superior structural platform for micro‐architectured metamaterials. The emergence of microvascular fiber‐composites, originally conceived for bioinspired self‐healing via microchannels filled with functional fluids, provides a unique pathway for dynamic reconfigurable behavior. Demonstrated here is the new ability to modulate both electromagnetic and thermal responses within a single structural composite by fluid substitution within a serpentine vasculature. Liquid metal infiltration of varying density micro‐channels alters polarized radio‐frequency wave reflection, while water circulation through the same vasculature enables active‐cooling. This latest approach to control bulk property plurality by widespread vascularization exhibits minimal impact on structural performance. Detailed experimental/computational studies, presented in this paper, unravel the effects of micro‐vascular topology on macro‐mechanical behavior. The results, spanning multiple physics, provide a new benchmark for future design optimization and real‐world application of multifunctional and adaptive microvascular composite metamaterials.

Natural processes continuously degrade a material’s performance throughout its life cycle. An emerging class of synthetic self-healing polymers and composites possess property-retaining functions with the promise of longer lifetimes. But sustained in-service repair of structural fiber-reinforced composites remains unfulfilled due to material heterogeneity and thermodynamic barriers in commonly cross-linked polymer-matrix constituents. Overcoming these inherent challenges for mechanical self-recovery is vital to extend in-service operation and attain widespread adoption of such bioinspired structural materials. Here we transcend existing obstacles and report a fiber-composite capable of minute-scale and prolonged in situ healing — 100 cycles: an order of magnitude higher than prior studies. By 3D printing a mendable thermoplastic onto woven glass/carbon fiber reinforcement and co-laminating with electrically resistive heater interlayers, we achieve in situ thermal remending of internal delamination via dynamic bond re-association. Full fracture recovery occurs below the glass-transition temperature of the thermoset epoxy-matrix composite, thus preserving stiffness during and after repair. A discovery of chemically driven improvement in thermal remending of glass- over carbon-fiber composites is also revealed. The marked lifetime extension offered by this self-healing strategy mitigates costly maintenance, facilitates repair of difficult-to-access structures (e.g., wind-turbine blades), and reduces part replacement, thereby benefiting economy and environment.

Fiber-reinforced polymer (FRP) composites, consisting of stiff/strong fibers embedded within a continuous matrix, are a lightweight structural platform supporting an array of modern applications. Bioinspired vascularization of fiber-composites can augment existing performance with dynamic functionalities via liquid infiltration of the internal micro-fluidic network. Some vascular-enabled capabilities include self-healing to repair delamination damage and active-cooling to prevent thermal degradation. While such attributes have been demonstrated in separate platforms, research investigations that combine functionalities within a single composite have been limited. Here we provide a recent study that highlights a promising pathway for achieving both multifunctional, and reconfigurable behavior in microvascular FRP composites. Specifically, we detail the ability to regulate temperature and modulate electromagnetic signature via fluid substitution within the same serpentine vasculature. Varying microchannel density alters both active-cooling efficiency by water circulation and polarized radio-frequency wave reflection by liquid metal infiltration. We control these bulk property pluralities by widespread vascularization, while minimizing impact on structural performance, and decode the effects of micro-vascular topology on macromechanical behavior. Our in-depth experimental and computational investigation provides a new benchmark for future design optimization and real-world translation of multifunctional and adaptive microvascular composites.

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Fiber-reinforced polymer composites are attractive structural materials due to their high specific strength/stiffness and excellent corrosion resistance. However, the lack of through-thickness reinforcement in laminated composites creates inherent susceptibility to fiber-matrix debonding, i.e., interlaminar delamination. This internal damage mode has proven difficult to detect and nearly impossible to repair via conventional methods, and therefore, remains a significant factor limiting the reliability of composite laminates in lightweight structures. Thus, novel approaches for mitigation (e.g., self-healing) of this incessant damage mode are of tremendous interest. Self-healing strategies involving sequestration of reactive liquids, i.e. microcapsule and microvascular systems, show promise for the extending service- life of laminated composites. However, limited heal cycles, long reaction times (hours/days), and variable stability of chemical agents under changing environmental conditions remain formidable research challenges. Intrinsic self- healing approaches that utilize reversible bonds in the host material circumvent many of these limitations and offer the potential for unlimited heal cycles. Here we detail the development of an intrinsic self-healing woven composite laminate based on thermally-induced dynamic bond re-association of 3D-printed polymer interlayers. In contrast to prior work, self-repair of the laminate occurs in situ and below the glass-transition temperature of the epoxy matrix, and maintains >85% of the elastic modulus during healing. This new platform has been deployed in both glass and carbon-fiber composites, demonstrating application versatility. Remarkably, up to 20 rapid (minute-scale) self-healing cycles have been achieved with healing efficiencies hovering 100% of the interlayer toughened (4-5x) composite laminate. This latest self-healing advancement exhibits unprecedented potential for perpetual in-service repair along with material multi-functionality (e.g., deicing ability) to meet modern application demands.