Feather‐inspired carbon fiber reinforced polymers with nanofibrous fractal interlayer

Much work has been performed in improving carbon fiber‐reinforced polymer (CFRP) composites to prevent delamination, which is the major defect in laminated composites. Nevertheless, there is not much focus on improving conventional CFRP systems in terms of weight, especially when these are used in primary structures. This article explores whether lighter and at the same time stronger CFRP composites can be manufactured to replace conventional CFRP systems in major applications. Under this perspective, and having established the fundamentals for creating the next generation of light weight structural composites—the featherweight composites—this work introduces a feather‐inspired case which uses a controlled interlayer reinforcement in a fractal and reproducible manner at the macro‐, micro‐, and nano‐scales. By extensively describing the matrix system and the manufacturing processes and focusing on analytically and thermomechanically testing the CNT (Carbon Nanotubes) reinforced nanofiber interlayer system, it is shown that this feather‐inspired CFRP achieves significantly higher mechanical properties as well as potential weight savings. POLYM. COMPOS., 168–181, 2016. © 2014 Society of Plastics Engineers