A Graphene Sensor for Defect Detection and Predictive Maintenance in Composite Materials (GRAPHOSITE)

A graphene sensor embedded inside a composite material will detect cracks and damage as they form, without needing expensive external scanning equipment. Composite materials—carbon fibre and similar laminates—are used in aircraft, wind turbine blades, and lightweight vehicles. But they can develop hidden defects during manufacturing or in service, and current detection methods like ultrasonic testing are costly and inconvenient. The UK Composites Strategy has identified this reliability gap as a barrier to expanding composites into new industries. GRAPHOSITE aims to solve this by exploiting an enhanced interaction between graphene and the material it sits on. The sensor becomes part of the structure itself, continuously monitoring for strain or damage and enabling predictive maintenance—repair before failure occurs. If successful, the technology could make composite components safer and cheaper to maintain across aerospace, energy, and transport sectors. The project forecasts cumulative revenue of £103 million after six years on the market, suggesting strong industrial appetite for a practical, embedded monitoring solution. This is applied engineering with a clear commercial pathway, not fundamental science.