Challenging six decades of convention, Chinese scientists have proposed a new composite material manufacturing method that could improve the strength and reliability of structures used in drones, aircraft and spacecraft.

By introducing an advance in the so-called balanced lay-up approach – a method of stacking fibre layers symmetrically and in opposing angles to minimise internal stresses – the research team reported strength gains of up to 26 per cent.

It also led to a 13 per cent improvement in joint performance, while reducing curing deformation during the manufacturing process that could result in defects.

The advance could broaden design flexibility across aerospace applications, as lower curing deformation means fewer distortions during production, according to a statement on March 9 from the Institute of Mechanics at the Chinese Academy of Sciences.

Greater design flexibility would be especially beneficial for high-precision components such as fuselages, wings and load-bearing panels, it added.