Next‐Generation Composite Materials and Manufacturing: A Review of Smart, Sustainable, and Digital Advancements

Abstract

ABSTRACT This critical review examines recent advances in sustainable digital composite manufacturing, focusing on aligning high‐performance composites with circular economy principles. It systematically evaluates next‐generation natural fiber reinforcements, recycled polymers, and bio‐based resins, alongside digital tools such as Artificial Intelligence (AI)‐driven design optimization and blockchain‐enabled supply chain transparency. Findings show that advanced bio‐resins and fiber treatments can reduce environmental impact by 40–60%, while digital twins and AI improve production efficiency by up to 30%. The review critically assesses the scalability and real‐world limitations of these innovations, highlighting gaps between theoretical potential and industrial adoption. It emphasizes how integrating sustainable materials with digital technologies enhances lifecycle sustainability, while identifying persistent challenges in cost, standardization, and system integration. By bridging materials science, sustainability, and digitalization, this work provides a forward‐looking roadmap for next‐generation composites. Emerging areas include smart composites, autonomous manufacturing, and self‐healing materials, all essential for meeting performance and environmental benchmarks. The review also examines intelligent composite systems with embedded sensing, self‐healing, and adaptive capabilities, highlighting their role in next‐generation applications. The study concludes that coordinated efforts in research, policy, and industry collaboration are essential to fully realize the potential of sustainable digital composite manufacturing.