Mr. Luca Mezzo, an independent composite expert with over 25 years of experience in advanced composites for defence, aerospace, and automotive sectors, recently spoke with Neeraj Tiwari, Senior Journalist at Marksmen Daily. Since 2018, Mr. Mezzo has been helping major corporations integrate lightweight composites into their operations, revolutionizing industries that rely on cutting-edge materials.
Q1:How do you think new materials and manufacturing technologies will improve space exploration and defence systems? Ans: New materials and advanced manufacturing techniques are transforming both space exploration and defence. In the space domain, lighter yet stronger materials cut launch mass, lowering costs while fortifying spacecraft against harsh conditions. In defence, these materials boost the performance of vehicles and weaponry while curbing overall ownership expenses. Moreover, innovations like additive manufacturing enable on-demand production, reducing costs and strengthening supply chain resilience.
Q2:How can lightweight composites help make electric and hybrid planes more efficient and save fuel? Ans: Lightweight composites, such as carbon Fiber-reinforced polymers, are essential for improving the efficiency of electric and hybrid aircraft. By reducing overall weight, these materials lower energy consumption and extend range—key advantages for battery-powered propulsion systems. Additionally, their design flexibility enhances aerodynamics and fuel efficiency, making next-generation aircraft more practical for both commercial and military use.
Q3:Are there any new technologies in the space sector that are using lightweight composites or advanced manufacturing techniques?
Ans: The use of advanced lightweight composites is rapidly expanding in the manufacturing of launch vehicles and satellite structures. To enhance quality, streamline production, and reduce lead times, additive manufacturing and 3D-printing technologies are playing an increasingly significant role in their fabrication. India has already demonstrated expertise in this area, with notable applications including rocket motor casings, pressure vessels, payload fairings, and ablative heat shields. These innovations contribute to more efficient, cost-effective, and high-performance space missions.
Q4:What problems do you face when using new composite materials in defence systems, and how are you solving them? Ans: There are two key challenges: accurately simulating material performance in extreme conditions—especially with limited publicly available data on similar environments—and minimizing costly physical testing. Additionally, predicting manufacturability and cost early in the development process is crucial. To tackle these challenges, we have developed a proprietary simulation tool for lightweight armoured products. This tool predicts the material required to withstand specific threats, estimates weight savings compared to traditional heavier solutions, and assesses material and manufacturing costs.
Q5:How important is sustainability when developing composite materials for aerospace and defence, and what steps are being taken to reduce their environmental impact? Ans: Sustainability is becoming a critical factor in material development; especially as aerospace industries work towards reducing carbon footprints. One major focus is on recyclable and bio-based composite materials, which can reduce reliance on petroleum-based components. Additionally, advancements in closed-loop manufacturing and waste reduction strategies are helping minimize environmental impact. Companies are also exploring energy-efficient production processes, such as automated Fiber placement and additive manufacturing, which reduce excess material waste compared to traditional manufacturing.
Q6:As an experienced Independent Composite Expert, how do you see 3D printing and AI helping improve the production of lightweight composite materials for space and defence? Ans: 3D printing and artificial intelligence (AI) have the potential to revolutionize labour-intensive processes in the manufacturing of lightweight composites. Additive manufacturing enables the creation of highly complex, optimized structures that were previously unattainable using conventional techniques. This not only reduces material waste and production costs but also enhances design flexibility and structural efficiency.
AI takes this to another level. The way it predicts how materials will perform—not just theoretically, but in practical, real-world applications—is impressive. It’s like having a crystal ball for engineers. Faster innovation can lead to breakthroughs that could change entire industries. And let’s not overlook the operational side—if AI can minimize errors and streamline processes, it empowers operators to focus on what really matters: creativity and quality. In sectors like aerospace and defence, the stakes are incredibly high, and every bit of efficiency or improvement can lead to significant advancements. We’re talking about the potential to revolutionize manufacturing and, indeed, the world as we know it. Embracing these technologies isn’t just smart; it’s essential for staying ahead in the game. The possibilities are endless, and this is just the beginning. It’s an exciting time to be pushing boundaries.
