Title Novel flexible photonic based sensors for health monitoring of composite structures

A new optical fibre design now measures strains hidden deep inside layered composite materials—strains that were previously invisible during manufacturing and throughout a structure’s lifetime. This matters because composite materials—used in aircraft wings, wind turbine blades, and lightweight vehicles—are built in layers. When those layers are pressed or cured, internal stresses can build up between them, leading to hidden damage or premature failure. Until now, no sensor could reliably measure those through-thickness strains. Manufacturers have had to over-engineer parts or scrap imperfect ones, wasting material and energy. If this research succeeds, the flexible photonic sensors will give real-time health reports during both production and service. Manufacturers could spot defects early, reduce scrappage, and extend the operational life of composite structures. That directly supports Net-Zero sustainability goals: fewer wasted materials, longer-lasting wind turbine blades, lighter aircraft that burn less fuel, and infrastructure that stays safe without being replaced too soon. The project works closely with industry to turn the sensor design into practical tools for manufacturing control and service-life prediction.