Advances in natural fiber polymer and PLA composites through artificial intelligence and machine learning integration
Authors:
Md. Helal Uddin, Mohammed Huzaifa Mulla, Tarek Abedin, Abreeza Manap, Boon Kar Yap, Reji Kumar Rajamony, Kiran Shahapurkar, T. M. Yunus Khan, Manzoore Elahi M. Soudagar, Mohammad Nur-E-Alam
The article discusses the shift towards sustainable materials in engineering, focusing on natural fiber polymer and PLA composites. It explores the integration of artificial intelligence (AI) and machine learning (ML) in enhancing the performance and sustainability of these composites. The text covers the environmental benefits, mechanical properties, and applications in industries such as automotive and aerospace. It also highlights the potential of AI and ML in predicting material behavior, optimizing manufacturing processes, and reducing waste. The article emphasizes the need for sustainable solutions in structural engineering and the role of AI in driving innovation in this field.
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Abstract
Natural Fibre Polymer (NFP) and Polylactic Acid (PLA) composites have received a lot of interest in a variety of sectors because they are environmentally friendly, renewable, and sustainable. Over the last decade, researchers have investigated the aspects of NFP/PLA composite development and optimization for a wide range of applications, including packaging materials, automotive components, construction materials, textile and apparel, biomedical devices, agricultural and horticultural applications, electronics, and consumer electronics. Furthermore, using Artificial Intelligence (AI) and Machine Learning (ML) methodologies has increased these polymer materials and associated technologies in their search for new potential ways to further progress in NFP and PLA composites. The purpose of this review paper is to present a complete overview of AI and machine learning applications in the synthesis and development of NFP/PLA composite materials. The subject matter includes the following research areas: material characterization, manufacturing, property prediction, durability assessment, sustainability analysis, and future perspectives, which demonstrate the potential and challenges of AI/ML in advancing NFP/PLA composite materials and technologies.
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Introduction
The advancement of fiber-reinforced polymer composites (FRPCs) has been significantly influenced by incorporating synthetic fibers like glass, kevlar, and carbon. These materials have proven essential in fulfilling the needs of a wide range of engineering applications. Nonetheless, as environmental sustainability becomes a major concern nowadays, there has been a shift towards using more eco-friendly materials in product design. This has resulted in a greater emphasis on the potential of renewable, environmentally friendly raw materials to create sustainable products. This exciting progress holds immense promise for the future of manufacturing [1‐5]. Aeronautics and automotive industries, for example, are always searching for stronger and lighter materials in their quest for advancement to improve the reliability and efficiency of their systems. Fiber-reinforced polymeric composites are ideal for this demand with their high strength, stiffness, and low density. These composite materials offer a perfect balance of durability and weight, making them the material of choice for forward-thinking industries. Figure 1 depicts the sustainable life cycle of NFPC and PLA composites, indicating that they can provide an eco-friendly alternative to conventional, petroleum-based plastics due to their biodegradability and reduced carbon footprint. However, NFPC and PLA composites and composites-based products can be recycled, composted, or subjected to controlled degradation processes at the end of their functionality, thereby returning to the environment with minimal ecological impact. This closed-loop cycle ensures that the materials are utilized efficiently, reducing waste and conserving natural resources, ultimately contributing to a sustainable manufacturing ecosystem.
Fig. 1
Sustainable life cycle of NFPC and PLA composites
FRPCs stand out in the scope of the modern days' materials due to the combination of their excellent physical and mechanical properties, versatility, and cost-efficiency. This makes FRPCs an interesting option for diverse applications such as military engineering, bridge construction, automotive industry, pipelines, wind energy, aerospace, and ballistic uses. Researchers have recommended the use of several environmentally beneficial natural fibers such as sisal [6] coconut [7], sugar palm [8], oil palm [9], bamboo [10], jute [11], bagasse [12], mallow [13], guaruman [14] and curaua [15] fibers (Fig. 1). These natural fibers not only offer financial benefits throughout the structure's lifespan but also contribute to a more sustainable future. FRPCs are truly revolutionizing industries by becoming essential structural elements. Their versatility and durability make them an attractive choice for a wide range of applications that can significantly make a positive impression on the global sustainability goal. The entwined focus on profitability, resource stewardship, and community well-being throughout the fiber lifecycle is shown in Fig. 2, which depicts the three cornerstones of sustainability in natural fibers: economic viability, environmental responsibility, and social equity.
Fig. 2
The three cores of sustainability in natural fibers
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Researchers have created novel methods to improve the performance of NFRCs, such as chemically altering the fiber surface or creating hybrid composites by combining several fibers into a single matrix. The strengths of various fibers are carefully combined in these hybrid NFRCs through rigorous engineering, producing a composite material with consistent qualities and improved performance. The resulting composite material's physical, mechanical, and thermal properties are substantially enhanced by hybridizing natural fibers with synthetic fibers in a polymer matrix [2, 16]. Numerous efficient techniques for discovering novel materials have been developed as a result of the relationship that has been found between a material's structure and qualities. Natural fibers are one kind of material that has been investigated; these resources are renewable and sustainable and can be used to create eco-friendly composites. These fibers are inexpensive, lightweight, renewable, biodegradable, and possess a high degree of specialized qualities. They are also readily found in nature. Natural fiber-based composite materials are becoming more and more used in a variety of manufacturing industries due to their sustainability [17].
These materials can have a range of properties, integrating mechanical, thermal, optical, electrical, chemical, and nuclear. Mechanical properties are exceptionally essential as they ensure the integrity of structures and prevent failures such as material degradation, cracking, buckling, and delamination. The composition and structure of mechanical materials must be constructed to attain desired mechanical qualities. This bears significance for numerous cutting-edge materials, such as metamaterials, bioinspired materials, and synthetic composites. However, designing these materials with traditional approaches might be challenging due to their intricacy [18].
In recent years, AI has demonstrated significant promise in addressing complex problems in various sections of science and engineering, especially in the areas of energy and building sustainability, materials, and mechanical properties evaluation and prediction [19‐21]. AI algorithms that are based on imitation and learning can be a great substitute for further experimental testing. ML which can identify the mapping from input data to output utilized for decision-making, is one of the most promising AI techniques. However, it can be challenging to manually extract appropriate features from raw data that is easy for humans to understand but complex for machines. Deep learning (DL), an explicit type of ML that can learn the representation of input data and parse it into multiple levels of abstraction using complex neural network structures, has emerged as a solution to this challenge. Simultaneously, Additive Manufacturing (AM), is a technology that makes it possible to construct three-dimensional (3D) CAD (Computer Aided Design) models into physical components by building them layer by layer until they are completed. A significant amount of research has been invested in exploring the numerous technical aspects of AM, spanning materials, processes, applications, and management. As opposed to conventional processes that remove undesired material in AM builds components layer by layer, utilizing materials with thicknesses ranging from a few microns to 0.25 mm [22].
Another significant aspect of this strategy is the use of ML to optimize the AM tool path to produce the highest-quality AM products with the best possible material and structure. This methodological approach demonstrates how data-driven models have the ability to completely transform additive manufacturing [23]. ML is now considered a successful approach for designing and discovering new materials for various applications [24] which was initially used to detect the solubility of C60 [25]. Experiments and testing on conventional machines play a vital role in characterizing novel materials. ML helps reduce the computational time and cost incurred during experiments, making it a valuable tool in the field of material science [26].
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Integrating AI and ML is becoming a new area of investigation in NFPC materials design and synthesis. The paradigm introduced by AI and ML enables NFPC research to progress more rapidly and gain deeper insights. With unprecedented speed and accuracy, these technologies can uncover intricate connections within NFPC materials, predict their behaviour under various conditions, optimize composite compositions, and anticipate future challenges. Real-time monitoring and analysis can ensure the performance and longevity of NFPC products, increasing their reliability in various situations. AI-driven simulations also allow for virtual experimentation, significantly reducing the time and resources required for actual trials.
Sustainable structural engineering continuously evolves with advancements and innovations in integrating PLA and recycled materials. PLA, or polylactic acid, combines sustainability with the properties of traditional polymers. It has been thoroughly explored and applied in various industries, including food packaging, textiles, and engineering plastics. These applications demonstrate the potential of PLA as a versatile and environmentally friendly material. Furthermore, ongoing research focuses on addressing the limitations of PLA, such as low impact strength and low heat distortion temperature. Efforts are being made to develop specialized PLA grades and explore the use of PLA in structural engineering, including its integration with recycled materials [27].
In today's world, the need for sustainable solutions in structural engineering is more important than ever due to the continuous growth of urbanization at a rapid rate, leading to an increasing demand for sustainable structural engineering solutions [28]. This demand arises from the recognition that traditional construction practices and materials substantially lead to environmental destruction, resource scarcity, and climate disruption. To address these challenges, researchers and engineers are exploring innovative approaches to integrate sustainable materials into structural engineering. One of the key areas of focus in this pursuit is the integration of PLA and recycled materials [29].
The field of sustainable structural engineering is continuously evolving, with a growing emphasis on the integration of innovative materials and technologies. These advancements are driven by the need to reduce environmental impact, conserve resources, and promote sustainable development. One area of particular interest is the integration of polylactic acid and recycled materials in structural engineering applications. PLA is a biodegradable and renewable polymer that has gained attention for its potential to replace traditional engineering plastics in durable applications. Recycled materials, on the other hand, offer a solution to the growing problem of waste accumulation by providing a sustainable alternative to raw materials. This review article aims to provide a comprehensive outline of the applications of AI and ML in NFPC and PLA research. It covers material characterization, manufacturing, property prediction, durability assessment, sustainability analysis, failure analysis, design, optimization, case studies, and future perspectives, showcasing the potential and challenges of ML in advancing NFPC and PLA technologies.
Understanding of AI/ML integrated emerging studies in NFP/PLA sustainable materials
Advances and innovations in PLA and recycled material integration in recent years, have been a growing interest and focus on sustainable structural engineering practices. The integration of polylactic acid and recycled materials in structural engineering has become a key area of interest for researchers and practitioners. Sustainable structural engineering involves the incorporation of environmentally friendly materials and processes to minimize the negative impact on the environment while providing durable and efficient structures. PLA, a biodegradable polymer derived from renewable resources like cornstarch or sugarcane, is gaining interest for its potential use in structural applications.
Recycled materials, on the other hand, offer a sustainable solution by diverting waste from landfills and reducing the need for virgin resources. The integration of PLA and recycled materials in structural engineering presents new opportunities and challenges that require a comprehensive understanding of material properties, structural performance, and environmental impact [30]. Researchers have explored various aspects of PLA and recycled material integration in structural engineering, including material characterization, mechanical properties, structural design approaches, and life cycle assessment. Understanding the behaviours of PLA composites and recycled materials under different loading conditions is crucial for the development of design guidelines and standards for sustainable structural applications [31].
Moreover, the environmental implications of utilizing PLA and recycled materials in structural engineering should be carefully evaluated in terms of energy consumption, carbon footprint, and end-of-life considerations. Life cycle assessment studies can provide valuable insights into the overall environmental benefits and trade-offs associated with the use of these materials in structural systems [28, 32, 33]. The integration of PLA and recycled materials in sustainable structural engineering presents a promising path toward achieving environmentally responsible and resilient infrastructure. However, further research and technological advancements are essential to fully exploit the potential of these materials and address the challenges associated with their implementation.
Natural fiber
An exciting innovation in polymer composites is the increasing utilization of natural fibers as reinforcement and filler materials. This trend has substantially contributed to the rapid expansion of natural fiber-reinforced polymer composites (NFRPCs), also represented as natural fiber composites (NFCs) (Fig. 3). These materials, which use natural fibers such as hemp, sisal, jute, kenaf, and flax as reinforcing materials in polymer-based matrices, have become increasingly valuable. With new environmental regulations, a growing emphasis on sustainability heightened ecological, social, and economic awareness, and the high cost of petroleum resources, the optimal use of natural resources has become more critical than ever [34], In the manufacturing and construction sectors, natural fiber-reinforced composites, or NFRCs, have been created for a variety of industrial uses. With encouraging outcomes, several investigations have been conducted to realise the possibility of using plant fibers as a natural source of reinforcement in polymer composites. These composites provide superior strength and durability over conventional materials in a way that is both sustainable and environmentally friendly [35, 36].
Fig. 3
Different varieties of natural fibers
Harnessing nanoparticles, like carbon nanotubes (CNTs), to alter the matrix has led to the creation of CNT-based polymer-reinforced nanocomposites with a variety of advantageous features for enhanced manufacturing and applications. Due to its outstanding strength, distinct properties, and topologies, CNT is a perfect reinforcement medium for a hybrid epoxy matrix. However, achieving the optimum stability of NFRCs requires the preparation and testing of multiple samples, leading to material wastage, increased time consumption, and higher production costs. This emphasizes the need for a model and optimization of the process [37‐40]. Figure 4 showcases how CNT–polymer composites are utilized across different industries, highlighting their unique properties such as enhanced mechanical strength, electrical conductivity, and thermal stability for various specific applications in fields such as electronics, aerospace, automotive, and energy storage.
Fig. 4
Application of CNT–polymer composites demonstrating the versatility and significance of these advanced materials
PLA materials
PLA is also a widely used material in additive manufacturing, also known as 3D printed materials [41, 42]. It is a biodegradable polymer which is mainly derived from renewable resources such as corn starch or sugarcane. PLA has gained popularity in the additive manufacturing industry due to its unique characteristics such as high biocompatibility, easy printability, and environmental friendliness due to less toxicity [43, 44] makes them desirable for a wide range of applications.
PLA in additive manufacturing ensures a safer working environment for manufacturers and users and thus sets PLA apart from certain other thermoplastics commonly utilized in 3D printing for a wide range of applications including medical and consumer products [44, 45] [30]. PLAs’ flexible nature offers to produce complex geometries enabling designers and engineers to be more innovative with the future sustainable products concepts. When processed under appropriate conditions, PLA can achieve smooth surface finishes and sharp edges, further enhancing its appeal for diverse manufacturing requirements.
Furthermore, the mechanical properties of PLA, including its stiffness, tensile strength, and impact resistance, make it a suitable material for a wide range of functional and aesthetic applications. With advancements in PLA formulations and additives, the material's mechanical performance has been continuously improving, expanding its potential use in demanding engineering and consumer product applications [46]. Therefore, as the additive manufacturing industry continues to grow and diversify, PLA remains a promising material choice for creating sustainable and high-performance products across various sectors [43].
Existing databases related to NFP/PLA composites
The use of natural fibers rather than synthetic ones has been one of the subjects of greatest study in recent years. This is due to their inherent qualities, which include their pleasant processing and greater biodegradability, renewable nature, and availability compared to synthetic fibers. The use of natural fibers rather than synthetic ones has been one of the most researched topics in recent years. This is due to their inherent qualities, which include their pleasant processing and greater biodegradability, renewable nature, and availability compared to synthetic fibers [47]. Data sets play a significant role in the training, validation, and evaluation of ML models. Natural fiber polymer and PLA are bioplastic polymers derived from plants that are rich in highly oxygenated molecules [48]. Material databases offer a vast array of information required for designing polymeric materials and chemical structures. The comprehensive database includes ChemSpdier [49], The Materials Project [50], Material Hub Springer [51],, PubChem [52], MatWEB [53], NIST [54], PoLyInfo [55], PolyIE [56], TPSX [57]. The composite natural fiber polymers such as rubber, polypropylene, polyester, unsaturated polyester, epoxy, high-density polythene, polybutylene succinates, and polylactic acid are derived from natural fibers [58]. Table 1 shows the existing database of polymer materials. The polymer properties can be found in the data set by their chemical name, molecular formula, structure, and other identifiers.
The database includes data sheets for thermoplastics, polymers such as ABS, nylon, polycarbonate, polyester, polyethylene and polypropylene other engineering materials
Descriptors for atomic structures are typically designed to represent the entire structure or a specific local atomic environment. Global descriptors capture information about the entire atomic structure and are used to predict properties such as molecular energies, formation energies, or band gaps. A typical workflow for predicting material properties using machine learning for atomistic structures involves transforming the atomic structure into a numerical representation. This descriptor serves as the input for a machine learning model, which is trained to predict the property of the structure. In some cases, the descriptor and the learning model can be combined into a single, inseparable process [59]. ML based descriptor model is illustrated in Fig. 5.
Fig. 5
The workflow of descriptor generation
Descriptors that encode atomic structures are typically designed to represent either the local atomic environment or the entire structure. Global descriptors capture information about the entire atomic structure and can be used to predict properties related to the structure as a whole, such as molecular energies, formation energies, or band gaps. In this study, we examine four such global descriptors: the Coulomb matrix, the Ewald sum matrix, the sine matrix, and the Many-Body Tensor Representation (MBTR). On the other hand, local descriptors represent specific regions within an atomic structure, making them suitable for predicting localized properties like atomic forces, adsorption energies, or properties that can be derived from local contributions [50, 57, 58]. Polymer descriptors are the typical characteristics that specify the properties and functionality of polymers; they are essential for material selection, optimization, and quality assurance. These descriptors include chemical composition, molecular weight and distribution, mechanical, thermal, rheological, and physical qualities. Usually, in the case of atomic structures, descriptors are devised either to describe the whole structure or some local atomic environment. Global ones like the Coulomb matrix, Ewald sum matrix, sine matrix, or MBTR define the entire atomic structure and are used mostly in a wide variety of property predictions. DScribe has been useful as an open-source library in the re-representation of atomic structures into fixed-size numeric vectors, specifically in a molecular system. Its application for macromolecular systems involving far greater order molecular weight values is quite unimplementable; it remains highly within ongoing exploration. For example, while the descriptors in DScribe summarise the properties of molecular systems in an effective way, few studies so far have used this on polymers, and most have been limited to using transfer learning to overcome challenges in polymer size and complexity; future research will need to be directed at modifying DScribe for such macromolecular intricacies [59]. A polymer's stability, compatibility, and reactivity are determined by its chemical composition, which includes the kinds of monomers and functional groups. The viscosity, mechanical strength, and thermal behavior of the polymers are influenced by molecular weight descriptors, such as polydispersity index (PDI), weight-average molecular weight (Mw), and number-average molecular weight (Mn). Processing and figuring out the operating temperature range depend heavily on thermal characteristics such as glass transition temperature (Tg), melting temperature (Tm), and degradation temperature (Td). For load-bearing applications and structural integrity, mechanical attributes including tensile strength, elastic modulus, and impact strength are essential. Processing ease in techniques like injection molding and extrusion is influenced by rheological parameters such as viscosity and flow behavior. Physical characteristics like density and crystallinity affect the polymer's buoyancy, weight, and mechanical performance. These characteristics are essential for forecasting performance directing the choice of materials and guaranteeing the effectiveness and caliber of polymer-based goods across a range of sectors, including packaging, automotive components, and medical devices. By comprehending and adjusting these characteristics, scientists and engineers can create sophisticated polymers with specialized attributes for specific applications. The polymer fiber descriptor types are presented in Table 2.
-Extensive calculations may demand significant computational resources
Molecular descriptors and fingerprints are vital for quantitative structure–activity relationships (QSAR), representing chemicals mathematically for model analysis
-Does not calculate as many descriptors as some software like DRAGON
-Developed using the Java language
-Easy integration to other QSAR software to provide the descriptor calculation feature
-The software uses a Master/Worker pattern
Sustainable materials in structural engineering
PLA traditional petroleum-derived plastics have been widely used in industrial and consumer products for their strength and durability. However, their disposal has resulted in harmful environmental impacts [69]. To address this challenge, the development of sustainable polymers has gained significant attention. Among these sustainable polymers, polylactic acid has emerged as a leading candidate. PLA-based plastics exhibit similar mechanical, thermal, and transparency properties as traditional plastics, making them a versatile and cost-effective alternative. Furthermore, PLA materials can be molded and fabricated using the same equipment and procedures as traditional plastics, making it easy for manufacturers to transition to more sustainable materials without major modifications to their processes. The material properties of PLA can be further enhanced through the use of nanocomposites, compatibilizers, plasticizers, and other fillers. These enhancements can improve the performance and functionality of PLA-based plastics, making them suitable for a wide range of commercial applications. PLA materials have distinct advantages such as being renewable, sustainable, biocompatible, and compostable (as explained in the lifecycle of PLA materials, Fig. 6). Moreover, PLA demonstrates significant potential to substitute traditional petrochemical-based polymers in industrial applications and to serve as a biomaterial in medical fields [30].
Fig. 6
Life cycle of PLA with AI integration
In addition, ML models, trained on datasets containing PLA materials information, aim to rapidly and accurately predict target mechanical properties or behaviours, or uncover compositions or structures surpassing those in the training data within the design realm, shown in Fig. 7 [18].
Fig. 7
Deep learning for mechanical property evaluation
Materials classification and characterization
Natural fibers are categorized based on their origin into plant, animal, and mineral fibers (Fig. 8). Each category contains fibers with unique properties and uses, ranging from textiles and insulation to composites and industrial applications. This classification helps in understanding the specific characteristics and potential applications of each type of natural fiber. Natural fibers are finding numerous uses in various industry sectors, such as sports, architecture, design, automotive, and many more, in light of environmental concerns and the depletion of non-renewable resources. Plant, mineral, and animal fibers are examples of natural fibers, arranged according to their origin. Plant fibers are made of cellulose, whereas animal fibers are mainly made of protein. Based on where they came from, plant-derived fibers can be further categorized. These fibers are perfect for use as fillers in a variety of applications since they are usually inexpensive and lightweight.
Fig. 8
Classification of natural fibers
The crystallinity and cellulose concentration, however, might differ greatly. For instance, the cellulose crystallinity of sisal fibers generated from leaves and kenaf bast fibers differs. Fibreboards and automotive components are two examples of items that frequently use bast fibers to improve their mechanical qualities. The major constituents of plant fibers are cellulose, hemicellulose, and lignin; waxes, pectin, moisture, and organic substances soluble in water make up the remaining portion.
Natural fiber is a composite material composed of rigid crystalline cellulose microfibrils embedded in a soft, amorphous matrix of lignin and hemicellulose. The properties of the fibers, and Natural Fiber Reinforced Composites (NFRCs), depend on their composition, microfibril angle, crystallinity, and internal structure. Cellulose, the primary component of natural fiber, has a strength and stiffness of > 2 GPa and 138 GPa, respectively. However, the stiffness of these natural fibers is particularly dependent on the microfibril angle. Therefore, fibers with a high cellulose content and a low microfibril angle tend to provide a high reinforcing effect in polymer composites. For instance, bast fibers, which have a higher cellulose content and lower microfibril angles, are often used. Other constituents of natural fibers, such as pectin and hemicellulose, influence other properties such as water absorption, wet strength, swelling, and integration of the fiber bundle. Therefore, a comprehensive characterization of natural fibers is crucial to achieve the desired strengthening in NFRCs. Natural fibers exhibit a wide range of fiber diameters, fiber bundle widths, and lengths, in addition to variations in fiber shape. These variations result in significant differences in the properties of polymer composites prepared using these fibers. Moreover, these variations pose substantial challenges in optimizing manufacturing processes where the fibers are used as reinforcement materials [26‐28, 44].
The diversity in the structure and dimensions of natural fibers, which includes aspects such as fiber density defined by the cell wall-to-lumen ratio and the angle of microfibrils, has a direct bearing on their mechanical properties. This, in turn, influences the mechanical properties of Natural Fiber Reinforced Composites as they are inherently dependent on the properties of the natural fibers they are composed of. Therefore, using data science and machine learning to study these materials can lead to breakthroughs in understanding their properties and potential applications, further emphasizing the importance of these novel materials in today's technological landscape. In the fascinating domain of machine learning, feature selection is a critical process. This involves the careful identification of key attributes that significantly influence the outcome. This process is particularly relevant in the study of Natural Fibre Polymer Composites (NFPCs), where factors such as fibre length, orientation, polymer type, and processing conditions are paramount. The length and orientation of the fibers directly influence the mechanical properties of a composite. For instance, composites enriched with longer fibers tend to exhibit enhanced strength and rigidity due to superior reinforcement. Fiber alignment and length are two critical factors in the enhancement of mechanical properties for composite materials. In fact, proper fiber alignment-especially in the direction of increasing tensile and flexural strength significantly, as observed in unidirectional carbon fiber/epoxy composites. The longer fibers further enhance the toughness and rigidity; studies have recorded a toughness improvement of up to 195% in UHPC. Such enhancements make fiber-reinforced composites highly suitable for demanding applications in aerospace, automotive industries, and sports industries [70‐73].
Ali Hasanzadeh et al., [39] predicted the mechanical properties of Basalt Fibre Reinforced High-Performance Concrete (BFHPC) with a simplified unit cell (SUC) model. This method allowed the compressive stress–strain curves to be simulated by Polynomial Regression (PR), in which, through their predictions of modulus of elasticity (ME), they attained a close approximation to experimental results and existing literature. Although not being a machine learning technique, the SUC model completes the approaches proposed to investigate mechanical properties with reduced experimental effort [36]. The models proposed in this study hold immense potential for practical applications in construction, offering a way to reduce extensive laboratory work, save time, and cut costs. The study concludes promisingly, suggesting that incorporating more reliable and high-quality experimental data could enhance model performance which can be useful for future research even to integrate machine learning techniques for even more precise outcomes.
In a pioneering study, Qi Zhenchao et al., [74] developed an innovative method for predicting the mechanical properties of carbon fibre. This method leverages cross-scale finite element modelling and machine learning to establish a complex relationship between Carbon Fiber Reinforced Polymer (CFRP) properties and its constituent fibre and matrix. The study revealed that the longitudinal elastic modulus (fE1) is primarily influenced by the elastic modulus of CFRP (E1). In contrast, the transverse elastic modulus (fE2/fE3) and shear modulus (fG12/fG13) are significantly affected by the elastic modulus of CFRP (E3) and the matrix (mE). The shear modulus (fG23) is determined by the shear modulus of CFRP (G12 and G23), and the elastic modulus and Poisson's ratio of the matrix (mE and mν). Decision tree models of varying depths were found to be optimal for predicting these properties. This approach provides a robust tool for predicting carbon fibre's mechanical properties, contributing to materials science advancements. Another critical factor is the type of polymer used for the matrix, which acts as the binding agent for the fibers, evenly distributes stress and protects against environmental factors [29, 64]. Different polymers can be combined to create composite materials with various properties. For instance, composites made with thermosetting polymers often exhibit higher resistance to solvents and heat than those made with thermoplastic polymers. Processing conditions, such as temperature, pressure, and curing time, also significantly impact the characteristics of NFPCs. These parameters determine the degree of fiber integration into the matrix, which influences the composite's mechanical properties and its efficiency in load transfer. Therefore, carefully selecting and manipulating these features can significantly enhance the mechanical properties of NFPCs, highlighting the importance of feature selection in machine learning within this context. Machine learning algorithms are ideally suited for the task of analyzing relationships between various features and the resulting properties of the composite due to their ability to handle complex, multi-dimensional data. To construct accurate predictive models, these machine learning models must be trained on datasets that contain information about these features and the properties of different NFPCs. Once trained, these models can be utilized to predict the properties of new, unseen composites, thereby significantly accelerating the development process. Moreover, machine learning algorithms can identify interactions between different features. For example, they may find that a specific combination of fibre length, orientation, polymer type, and processing conditions results in a composite with exceptional properties. Such insights could lead to discovering new NFPCs with unique properties, opening up new avenues for research. AI/ML is revolutionizing the field of engineering and material science, particularly in the study of NFPCs [25‐29].
AI/ML has made a substantial contribution to predicting the mechanical properties of NFPCs. These models can accurately forecast a range of mechanical properties, including tensile strength, modulus of elasticity, and impact resistance, by analysing the composition and processing parameters of NFPCs. This reduces the need for extensive experimental testing, accelerating the development process and optimizing resource utilization. Understanding how and why materials fail under various loading conditions allows researchers and engineers to develop strategies to mitigate these failures, thereby enhancing the reliability and lifespan of composites. This insight is vital for designing NFPCs with improved toughness and durability. AI/ML also proves beneficial in sensitivity analysis. Machine learning models facilitate this analysis by identifying critical parameters influencing the mechanical properties of NFPCs. Sensitivity analysis involves examining the impact of each feature on the model's prediction. A significant change in the model's outcome due to a change in a feature value indicates that the feature has a substantial impact on the prediction. By identifying the most influential factors, researchers can concentrate their efforts on enhancing specific features of NFPCs, refining the manufacturing process, and optimizing the material composition for improved performance [25, 37, 38].
The mechanical properties of composite materials were studied by employing Deep Learning (DL) prediction to figure out the accuracy of the mechanical properties’ evaluation using correlation analysis between factors and their mechanical properties. Python was used to analyze the impact strength of natural fiber-reinforced PLA biocomposites, considering factors such as chemical composition, density, dimensions, surface treatment, matrix-reinforcement volume fraction, and manufacturing processing type, depicted in Fig. 9. In [75] 27 data from the provided information for DL modeling. The data yields an impact strength output with a mean of 19.86 kJ/m2 and a standard deviation of 11.97 kJ/m2, with a minimum value of 5.00 kJ/m2 and a maximum value of 56.00 kJ/m2 (Fig. 9a). Figure (9b) displays the results of the correlation study that was done between each characteristic. Certain characteristics have a strong correlation with one another, such as lignin (93%), hemicellulose (89%), and cellulose (100%). One of the strongly associated characteristics has to be eliminated in order to get decent DL regression model performance. Figure (9c) illustrates the relationship between the attributes and the result (impact strength). The results of the study show that characteristics and impact strength output are correlated, with certain features showing almost zero correlations. These consist of cellulose, fibre density, chemical treatment applied to the fibre surface, and processing techniques. The study indicates that hemicellulose, lignin, pectin, wax, moisture content, fibre diameter, and fibre content are the seven characteristics that are critical for a deep learning model to function well. The performance of the model is significantly impacted by these features. The correlation values are 0.055, 0.086, 0.098, −0.066, and 0.055. Table 3 summarizes the objective and findings of NFRC and PLA applications in AM with AI/ML integration.
Fig. 9
Composites reinforced with natural fibers and their output correlation coefficient (a) feature statistics (27 data), b correlation coefficient matrix, and (c) correlation coefficient output [75]
Table 3
Summary of NFRC and PLA application in AM with AI and ML embedded [Timeline: 2019–2024]
Develop and validate a bidirectional gated recurrent neural network to predict machining conditions from acoustic emission signals in natural fiber-reinforced polymer composites, aiming to enhance process monitoring
Bidirectional gated recurrent neural network models predict machining conditions from acoustic signals in natural fiber composites with ~ 87% accuracy
Bamboo fiber-reinforced PLA composites, focusing on mechanical properties, thermal characteristics, sustainability aspects, utilization in various industries, and the effects of 3D printing parameters
Bamboo fiber-reinforced PLA composites are eco-friendly and strong but limited in aerospace and humid environments
3D Printed PLA-Natural Fiber Composites: Tensile Behavior
Experimental
Fabrication: Blend PLA with henequen flour, 3D print at 0° raster angle for tension tests. Characterization: Density, porosity, crystallinity, microscopic analysis
Investigate the mechanical properties of 3D printed PLA composites reinforced with henequen flour, assessing effects of flour content, raster angles, and maleic anhydride addition, with emphasis on understanding reinforcement mechanisms and optimizing composite performance
Henequen fiber-PLA composites enhance 3D print strength but face particle clumping and void issues, needing optimization
Develop machine learning-assisted models for the analysis, design, and optimization of polymer composite materials
Machine learning-assisted modeling enhances the analysis, design, and optimization of polymer composite materials, facilitating advancements in material science and engineering
AI Predictions for Fiber-Reinforced Polymer Composite Residual Strength
Review
-
Develop an artificial neural network framework incorporating dielectric state variables for predicting fatigue life and residual strength of fiber-reinforced polymer (FRP) composites under dynamic loading conditions
Artificial neural network framework using dielectric state variables predicts fatigue life and residual strength of fiber composites under dynamic loading but requires refinement for broader applicability
Hybrid Additive Manufacturing of PLA-Carbon Fiber Composites: Optimization and ML
Experimental
The methods involve hybrid additive manufacturing to create PLA-Carbon Fiber-PLA sandwiched composites, followed by optimization using machine learning techniques
Optimize and enhance the fabrication of sustainable PLA-Carbon Fiber-PLA sandwiched composite structures using hybrid additive manufacturing and machine learning techniques
Hybrid AM and ML optimization improve PLA carbon fiber composite properties. Ideal conditions: 00 carbon fiber orientation, 205 °C nozzle, 55 °C bed temp
Machine Learning for Natural Fiber Composite Property Analysis
Experimental
Evaluated 26 natural fiber composites with varied reinforcements and manufacturing methods. ML-based approach analyzed interrelations of properties like density, tensile strength, and hardness
Utilize a machine learning-based approach to discover the relationships between the properties of natural fiber composites, facilitating the selection of suitable materials for various applications
ML reveals natural fiber composite property relationships, aiding selection, yet requires validation and refinement for broader applicability
Examine the machining characteristics, failure mechanisms, and the influence of process parameters in both conventional and unconventional machining of natural fiber composites
Challenges in machining natural fiber composites due to their heterogeneous and anisotropic behavior
Various methodologies to improve machinability; complexities of machining these materials effectively
Challenges and Opportunities in NFRC Industrial Applications
Review
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The challenges and opportunities associated with the utilization of natural fiber-reinforced polymer composites in diverse industrial applications, emphasizing their potential as sustainable alternatives and identifying areas for further research and development
Natural fiber-reinforced polymer composites show promise in automotive and furniture industries. Challenges include temperature stability and moisture absorption mitigation for full benefit utilization
The application of deep learning in the design and behavior prediction of modern composite materials systems
Deep learning has potential but faces challenges: high-quality data, model interpretability, and addressing fabrication-induced defects and damage evolution, hindering adoption in heterogeneous composites
Green PLA Composites from Agricultural or Marine Waste via FDM
Experimental
The study utilized lignocellulosic fillers from Opuntia focus indica and Posidonia oceanica, ground into flour and integrated into PLA matrix at two loading levels, with 3D printing conducted via FDM to assess the feasibility of producing green composites
Assess the feasibility of FDM in producing green composites using lignocellulosic fillers from agricultural and marine waste, integrated into PLA matrix
FDM-produced green composites with up to 20% natural fillers show similar mechanical properties to neat PLA. Increased hydrophilicity may boost biodegradability, but stability against thermomechanical degradation and filler-matrix interactions need further improvement for high mechanical performance applications
The composite samples were prepared using compression molding with unidirectional fiberorientation, incorporating five different fiber loadings (25, 35, 45, 55, and 65 wt percent) of 100 mm long alkaline-treated abaca fibers into a high impact polyethylene matrix, followed by tensile, hardness, and density testing to assess the influence of fiber loading on mechanical properties
Investigate the effect of fiber loading on the mechanical properties of high impact polyethylene composites reinforced with alkaline-treated abaca fiber
Composite's tensile strength and Young’s modulus improve with higher fiber loading, optimal at 55%. Hardness and density show slight increases, but uneven fiber distribution affects consistency, highlighting the need for improved fiber-matrix adhesion
Mechanical Properties of Natural Fiber Polymer Composites at Different Strain Rates
Review
-
The mechanical properties and failure behaviors of natural fiber reinforced polymer composites under various loading conditions and strain rates, highlighting key factors, characterization techniques
Polymer composite strength typically increases with strain rate until debonding occurs. Challenges include refining strain rate-dependent testing and exploring nano-filler and hybrid reinforcements for improved performance
AI Model for Predicting Young’s Modulus of Polymer/Carbon Nanotube Composites
Review
-
Develop an AI model using Artificial Neural Networks for predicting the Young’s modulus of polymer/carbon-nanotube composites, aiming to streamline the study of novel composite materials
AI model shows strong Young’s modulus prediction, but requires optimization for computational efficiency and resource use in practical deployment
"AI-Optimized Orthopedic Plate Coating with PCL/Akermanite Nano-Fibers"
Experimental
3D print PLA orthopedic plates, coat with electrospun PCL/Akermanite nano-fibers, assess thermomechanical properties and bioactivity using diverse characterization methods
Investigating the thermomechanical properties of 3D-printed orthopedic plates coated with PCL/Akermanite nano-fibers and optimizing the data using machine learning algorithms
The addition of polycaprolactone and akermanite nano-fibers enhances mechanical properties of orthopedic plates. Coating PLA with PCL boosts max pressure force by 16.83% and bending flexural force by 21.06%. Further nAKT addition increases these forces by an extra 4.72% and 21.39%
Manufacturing and processing of NFP/PLA
AI technology uses various methodes, including as self-correction, reasoning (using rules to arrive at approximate or definitive conclusions), and learning (assimilating information and rules). AI is used in machine vision, speech recognition, and expert systems. Artificial Intelligence is acknowledged for its capacity to comprehend its surroundings and formulate the optimal plan of action to accomplish preset goals. AI is divided into two subcategories in the industrial domain: ML which uses data to improve a task's performance without explicit programming, and Deep Learning, which is a related technique that usually uses larger data sets and more complex logic networks to improve performance (Fig. 10).
Fig. 10
Features of ML process (a), and algorithm classification (b)
ML techniques are perfect for this purpose because they can examine the connections between these features and the final qualities of the composite. One major advantage is their capacity to manage multidimensional, complicated data. ML models require to be trained using datasets that contain details on these attributes and the characteristics of various NFPCs for creating predictive models with higher accuracy. The development process can thus be greatly accelerated by using these models to forecast the properties of brand-new, untested composites.
AI integration in the industrial sector has created new opportunities for innovation, especially in the composites manufacturing sector. AI provides a wide range of deployment prospects for composite manufacturing, encompassing applications, products, and processes. This quickens the creation of applications and speeds up the improvement of goods and procedures. AI's introduction opens the door to new manufacturing in the future and allows for higher-quality, more productive production methods. These cutting-edge tools have expedited material selection, sped up simulations, and drastically cut expenses and time.
Moreover, these technologies are being employed to enhance the process parameters' development, which will improve the created components' buildability and characteristics. This creative method increases output and significantly improves the quality of the components that are produced. By combining AI and ML into the process of creating natural fibre polymer composites, manufacturing is about to undergo a radical change that will usher in a period of higher-quality and more productive production methods [45]. New paths have been shown for improving composite forming processes, controlling quality, bolstering overall quality, and real-time monitoring of process performance through the integration of AI and ML.
Overview of AI/ML techniques relevant to NFP and PLA composites
Artificial Neural Networks (ANNs), Convolutional Neural Networks (CNNs), Gradient Boosted Regression Trees (GBRT), and Deep Multi-Layer Perceptrons (Deep MLPs) each offer unique strengths for modeling and prediction tasks. ANNs excel in capturing complex, nonlinear relationships through multiple layers of interconnected nodes, making them versatile but potentially prone to overfitting without sufficient regularization. CNNs, with their specialized architecture for processing grid-like data (e.g., images), effectively capture spatial hierarchies and patterns, though they require substantial computational resources and large datasets for training. GBRT, a robust ensemble technique, excels in handling heterogeneous data and complex interactions with strong predictive accuracy but can be sensitive to noisy data and outliers. Deep MLPs, an extension of traditional MLPs with many hidden layers, offer superior performance in capturing intricate patterns and relationships within large datasets, yet they demand significant computational power and careful tuning to avoid overfitting. In comparison, while ANNs and Deep MLPs provide powerful modeling capabilities,
CNNs surpass traditional machine learning methods like random forest ensembles and linear regression. The study examines how CNN performance scales with dataset size compared to traditional ML methods and leverages CNN architecture flexibility to enhance performance with smaller datasets. Visualizing CNN convolution filters helps reveal the learned features and demonstrates its capability to hierarchically develop representative features. CNNs learn hierarchical unit cell features, and using deep learning to accelerate FEM calculations opens up the exciting potential for discovering new composite designs through high-throughput computation and optimization [76]. CNNs are best suited for tasks involving spatial data, and GBRT offers strong performance with structured data, though it may be less effective for very high-dimensional feature spaces. Understanding the constitutive laws, defect detection, impact dynamic response, tribological behavior, and fatigue failure of Fiber Composite Materials (FCMs) is crucial in various industries due to the influence of factors such as fiber arrangement and matrix characteristics on their mechanical properties. The anisotropic and heterogeneous nature of FCMs often necessitates costly experiments with low reproducibility and computationally intensive simulations for research into their mechanical behavior. Machine learning (ML) methods present a significant advantage in this context by enabling rapid discovery of data relationships and offering high reproducibility. The advancement of FCM manufacturing and testing techniques has generated large volumes of data, further enhancing the applicability of ML. Recently, ML methods have been increasingly utilized for predicting mechanical properties and optimizing material design. For example, Random Forest (RF) models have successfully predicted flame-retardant parameters of polymer composites with metal hydroxide additives, while artificial neural networks (ANN), support vector machines (SVM), and RF have predicted the compressive modulus of hybrid aerogels composed of two-dimensional transition metal carbides and nanocellulose. Similarly, deep neural network (DNN)-based models have been used to predict the tensile strength of polymer concrete, thus reducing manufacturing and testing costs. DNN is a feed-forward neural network with many layers of transformations and nonlinearity [77]. The output of each layer feeds the next layer ML methods excel in processing complex, multidimensional datasets, extracting nonlinear relationships, and eliminating the need for extensive constraints. Among these, Deep Multi-Layer Perceptron (Deep MLP) networks, with their multiple processing layers, are particularly effective in capturing intricate patterns within data. In the realm of FCMs, Deep MLP models can predict and analyze mechanical properties such as tensile strength, modulus of elasticity, and flexural yield strength from extensive datasets. Overall, ML methods, including Deep MLPs, play a pivotal role in rapidly constructing constitutive models and establishing relationships between FCMs' mechanical properties. They significantly enhance the efficiency of material performance predictions, and accelerate the design, characterization, and optimization of FCMs, showcasing their immense potential in advancing the field [78]. Machine learning methods such as k-nearest neighbor (KNN) and support vector machine (SVM) are widely applied in various fields. KNN is popular for its simplicity and low computational cost, and its performance can be enhanced with weighted KNN using a squared inverse feature weighting algorithm. KNN consistently demonstrates high accuracy. This approach automates the prediction of polymer rheological parameters, reducing research and development time and costs. Additionally, the model can be easily adapted to analyze different polymers and predict their properties [79]. Polymers are integral to daily life, yet their vast diversity presents challenges in identifying application-specific candidates. polyBERT is an NLP (Natural Language Processing)-inspired polymer informatics pipeline that rapidly and accurately predicts properties by treating chemical structures as a language [80]. TransPolymer, a Transformer-based language model for polymer property prediction, leverages a chemically aware tokenizer to learn polymer sequence representations. Rigorous testing on ten benchmarks shows its superior performance, benefiting from pretraining on large datasets [81]. PolyNC, a language model for polymers, combines natural language and SMILES inputs to predict properties and classify polymers. Trained on 22,970 data points, it excels in both property prediction and classification, advancing structure–property understanding in polymer science [82]. ChemBERTa, which demonstrates competitive performance on MoleculeNet and leverages a 77 M SMILES dataset from PubChem for self-supervised learning, is based on the RoBERTa transformer implementation in HuggingFace [83]. SMILES-BERT, a semi-supervised model that employs an attention-based Transformer Layer and utilizes large-scale unlabeled data for pre-training via a Masked SMILES Recovery task [84]. Mol-BERT, is an effective molecular representation method an end-to-end framework that leverages a pre-trained BERT model to extract molecular substructure information for property prediction [85]. The detailed ML/DL techniques are presented in Table 4.
Table 4
ML/DL techniques relevant to NFP and PLA composites
ANNs were used to predict the shear stress–strain behavior of carbon fiber/epoxy and glass fiber/epoxy composites.
A multilayer perceptron (MLP) neural network with the Levenberg–Marquardt learning algorithm was employed, with adjustments made to network architecture and training data.
Predicting stress-strain curves of binary composites using PCA and CNNs to improve computational efficiency and accuracy.
CNN
Applied PCA (principal component analysis) for dimensionality reduction of stress-strain curves, then used a fully convolutional neural network for prediction, trained with 1800 FE simulations and evaluated with 10-fold cross-validation.
90%
- PCA and CNN provide rapid, precise stress-strain predictions.
-Speeds up composite design and optimization.
-Dataset size (10-27% of configurations) affects generalization.
Use Transformer encoder with Masked Language Modeling for effective polymer property prediction.
TransPolymer
Transformer-based architecture with masked language modeling (MLM) for polymer property prediction, utilizing a multi-layer perceptron (MLP) regressor head for classification.
98%
-Effectively captures complex chemical representations-Polymer tokenization strategy
-Not comparable to the best baseline model without data augmentation
A transformer framework designed use GNN for predicting molecular properties, utilizing a carefully curated dataset of 77 million SMILES from PubChem
ChemBERTa
Uses 12 attention heads and 6 layers, resulting in 72 distinct attention mechanisms and baseline models D-MPNN, Random Forest, and SVM using 2048-bit Morgan fingerprints.
97%
-MLM pretraining provides a boost in predictive power
- Enhanced representations through supplementary data.
- The current analysis addresses only a limited aspect of the hypothesis.
Comprises six Transformer Encoder layers; a two-stage SMILES-BERT model leverages both unlabelled and labelled data for improved molecular property prediction.
SMILES-BERT
A semi-supervised learning method uses Adam optimizer for pre-training; the transformer layer comprises a pre-attention feedforward network, a self-attention layer, and a post-attention feedforward network.
91%
-Leverages large unlabelled datasets for pre-training, enhancing data variety
-Utilizes encoder-decoder structure for improved fine-tuning performance
-Lack of classification capability limits its performance, which could improve by integrating
Includes three modules: feature extractor, pretraining, and fine-tuning, using the ADAM optimizer for final property prediction with a multi-type of classifier.
MOL BERT
An end-to-end deep learning framework for large-scale predictions, adaptable for diverse molecular property tasks.
92%
-Surpasses traditional and advanced graph-based models in predicting molecular properties
-Limitations in regression due to small datasets
MLDS schemes for polymers and current developments
Machine Learning Descriptor Schemes (MLDS) are structured methodologies designed to transform the intrinsic features of complex systems such as materials, molecules, or polymers into quantitative representations, known as descriptors, that are amenable to processing by machine learning algorithms. These descriptors encapsulate the fundamental characteristics of the system, thereby enabling machine learning models to predict its behavior, properties, and performance with greater accuracy and efficiency. Machine learning descriptor schemes for polymer composites have been developed to predict various properties efficiently. Studies have shown the successful application of machine learning models in polymer informatics, where descriptors based on reaction energies and activation barriers of elementary reactions in radical polymerization were used to predict physical properties of copolymers with high accuracy. Polymer informatics, which involves the application of data-driven science to polymers, has attracted considerable interest [95]. Takayoshi Yoshimura et all, 2024, computed parameters for 2500 radical-monomer pairs from 50 monomers. Built machine learning models using computed descriptors and physical properties. These models achieved high predictive accuracies, demonstrating the potential of our descriptors to advance the field of polymer informatics. The copolymer database provides a descriptor scheme for copolymers, enhancing machine learning models for polymer informatics by predicting physical properties accurately based on radical-monomer pairs [95].
Yuuki Sugawara et al., 2023, utilize state-of-the-art machine learning (ML) methods to analyze and predict the lower critical solution temperature (LCST) of N-isopropyl acrylamide (NIPAAm) copolymers. This approach is aimed at systematically elucidating the relationship between various parameters and the LCST. A comprehensive dataset comprising information on 110 NIPAAm random copolymers is compiled from existing literature. This dataset includes both the LCST values and the chemical and physical parameters of the copolymers and their comonomers. The ML analysis identifies key parameters that significantly influence the LCST, such as the copolymerized ratio, the elemental composition of carbon and oxygen in the comonomers, and the water solubility of the comonomers. A genetic algorithm is employed alongside symbolic regression to derive a simple and comprehensive descriptor for predicting the LCST. This method enhances the understanding of the factors affecting polymer properties. These methods collectively demonstrate the effectiveness of data-driven ML techniques in advancing polymer research [96].
Developing Machine Learning Descriptor Schemes (MLDS) for polymers is a complex endeavor, primarily due to the intricate and diverse structures that polymers can possess. Capturing the full range of properties through descriptors is challenging, as these structures often exhibit a high degree of variability in terms of molecular weight, branching, and crosslinking [97]. This complexity is compounded by the scarcity of high-quality experimental data, which limits the ability to train machine learning models that are both accurate and generalizable. The interdisciplinary nature of this work requires a deep integration of knowledge from chemistry, materials science, and machine learning, creating a significant hurdle for researchers aiming to develop effective MLDS for polymers [98].
However, the advantages of MLDS are compelling: they offer powerful predictive capabilities that can significantly reduce the need for labor-intensive and time-consuming experimental procedures, thereby accelerating the discovery and optimization of new materials. Additionally, MLDS can be customized to focus on specific properties or performance criteria, providing a tailored approach that enhances the precision and relevance of predictions. This is particularly valuable in the context of natural fiber-reinforced polymers, where the variability in fiber properties and the interactions between the fiber and matrix further complicate the modeling process [99]. Despite these challenges, ongoing advancements in ML algorithms and computational resources continue to improve the robustness and applicability of MLDS in polymer science. The validation of Machine Learning Descriptor Schemes (MLDS) is a crucial step in ensuring their accuracy and effectiveness in predicting material properties or behaviors. Validation typically involves the application of rigorous testing protocols, such as cross-validation, to evaluate the performance of MLDS against experimental or simulated datasets. This process is essential for identifying the strengths and limitations of the descriptors, thereby ensuring that the machine learning models built upon them are both reliable and generalizable to novel, unseen data. Recent developments in MLDS for natural fiber composites focus on enhancing the granularity of descriptors to better capture the diverse characteristics of natural fibers, such as fiber orientation, aspect ratio, and surface treatment effects. Advanced MLDS schemes are increasingly integrating multi-scale modeling approaches, combining microscale fiber properties with macroscale composite behavior, to create more holistic and accurate descriptors. Additionally, the incorporation of domain knowledge into the MLDS framework is gaining traction, enabling more informed feature selection and improved model interpretability. Besides all these advances, challenges remain, particularly in addressing the stochastic nature of natural fibers and ensuring that MLDS frameworks are generalizable across different fiber types and composite matrices [100].
Hemavathi et al., 2024, use of machine learning are proving invaluable in researching renewable energy materials, particularly in polymer composites. This review discusses various supervised ML models and techniques, such as neural networks, Boltzmann machines, and algorithms like ANN, GA, GPR, SVR, and SVM, which are used to predict material properties and optimize energy applications. Key advancements include the use of deep learning for screening organic solar cells and closed-loop systems for energy storage. Despite its promise, challenges remain in improving ML techniques for accurate predictions and exploring inorganic materials. Overall, ML and AI are expected to drive significant progress in discovering and optimizing energy materials, enhancing efficiency, and reducing traditional research time [101].
Elaheh Kazemi-Khasragh et al., 2024, explore two computational methods such as Group Interaction Modelling (GIM) and ML for predicting six different thermal and mechanical properties of polymers. The ML approach employed the Random Forest (RF) algorithm, utilizing molecular descriptors derived from polymer chemical structures. The study demonstrated that ML models achieved high predictive accuracy with R2 values ranging from 0.83 to 0.955 for various properties, surpassing the GIM method, which relies on physical input parameters such as Debye temperature. The ML approach was particularly effective in predicting properties like heat capacity and glass transition temperature, showcasing its potential for reliable and efficient polymer property prediction. The study finds that the Random Forest (RF) machine learning approach significantly outperforms GIM in predicting the thermal and mechanical properties of polymers. The RF method, which uses molecular descriptors derived from polymer chemical structures, achieves high accuracy with R2 values ranging from 0.83 to 0.955 for properties such as Debye temperature and glass transition temperature. This advantage lies in the ML approach's ability to provide reliable predictions with fewer dependencies on complex physical parameters, unlike GIM, which depends on accurate Debye temperature values. However, the GIM method's accuracy is constrained by the precision of these input parameters, which can limit its effectiveness compared to the more straightforward ML approach [102].
Smart manufacturing process planning
ML-based applications in smart factories cover a wide range of areas, from predictive maintenance to process optimization. These technologies are essential for achieving sustainable and efficient manufacturing. ML technologies possess the potential to revolutionize the planning of manufacturing processes for NFPCs. Their ability to analyze intricate, multi-dimensional data makes them ideal for this kind of work. ML-based applications identify the relationships between a wide range of features and the final composite properties. This is accomplished by using extensive datasets that contain details about these features and the characteristics of various NFPCs to train machine learning models. After these models are sufficiently trained, they can accurately predict the characteristics of new, untested composites, which can greatly speed up development (Fig.11).
Fig. 11
Smart manufacturing with AI operations
Muruganandam, 2023 et al., reported the advancement of deep learning algorithms in smart manufacturing. smart factories frequently use ML-based applications to increase efficiency and productivity. In smart factories, ML applications are primarily utilized for identification, detection, and prediction tasks. A machine learning application determines the precise requirements needed to complete a task in smart factories. In smart factories, a predictive maintenance strategy is employed to anticipate issues before they arise. Machine learning techniques are among the most effective methods employed in the process of identification and classification. Additionally, smart factories that identify value information and generate data for the manufacturing system use machine learning (ML)-based evaluation applications. In smart factories, applications or methods based on the K-nearest neighbor (KNN) algorithm are used to identify potential issues as well as their root causes. KNN decreases the error and disaster level in smart factories which increases the efficiency of a fabrication system. Deep learning (DL) techniques are used to manage a huge amount of data. DL techniques provide analytics tools for data processing and analyzing systems. The figure shows smart manufacturing with AI operations [103].
In addition to classifying manufacturing features based on boundary representations in solid models, ML-based applications can be influential in establishing smart manufacturing capabilities. An AI-driven reasoning engine can be deployed in the background to evaluate specific designs and provide direct feedback to the designer regarding their manufacturability.
The integration of ML into the planning of NFPC manufacturing processes can lead to more streamlined and economical production processes, ultimately propelling the field forward. This novel method not only increases productivity but also makes a substantial contribution to the field's advancement.
Integration techniques and innovations add NFPC and PLA
Integration techniques and innovations in Natural Fiber Polymer Composites (NFPC) are significantly enhancing material performance and sustainability. Hybrid additive manufacturing combines traditional methods with 3D printing for precise fiber alignment, while machine learning optimization predicts and fine-tunes composite properties. Advanced fiber treatments improve fiber-matrix adhesion, and multi-material printing allows for tailored composite properties. Sustainable production methods emphasize eco-friendly processes and materials, and continuous fiber reinforcement boosts mechanical strength for demanding applications. These advancements collectively drive the development of superior, environmentally friendly NFPCs suitable for a wide range of industrial applications. In recent years, there has been a surge of research and development aimed at enhancing the properties and applications of PLA. One area of focus has been the integration of PLA with other materials through blending techniques. Blending PLA with other materials offers the potential to improve its mechanical properties, thermal stability, and overall performance. By incorporating renewable polymers or biodegradable materials, the toughness of PLA can be significantly enhanced [27]. While PLA, Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), and other 3D printing materials have gained popularity, On the other hand, it is important to consider the benefits of using these materials. One case study highlights the successful integration of PLA in the field of biomedical applications [44].
NFP and PLA integration focus on enhancing sustainability and mechanical performance. Methods such as hybrid additive manufacturing and machine learning optimization have significantly improved the properties and processability of NFPC and PLA composites, making them attractive alternatives for various industries, particularly automotive and furniture. The addition of natural fibers to PLA not only improves mechanical strength and biodegradability but also presents challenges like moisture absorption, temperature stability, and uniform fiber distribution. These challenges necessitate ongoing research and development to fully realize the potential of these eco-friendly composites. Additionally, advancements in fiber-matrix adhesion and the incorporation of nano-fillers could further enhance the performance and durability of NFPC and PLA composites, expanding their application scope.
Within the scope of AM, there has been a significant increase in the adoption of methods based on data-driven paradigms and artificial intelligence. These methodologies exploit the prowess of AI or Machine Learning algorithms to augment the design, process orchestration, and real-time surveillance of AM operations, especially those pertinent to polymeric composites. A comprehensive schematic representation of the complex processes involved in additive manufacturing, emphasizing the symbiotic relationship between design, process, structure, property, and performance. It emphasizes the significance of data-driven models in improving performance measures and maintaining structural integrity. Every stage of the production process is carefully examined and enhanced using adaptive control systems to guarantee that the finished product is the pinnacle of perfection in terms of both appearance and functionality. The Process-Structure–Property-Performance (PSPP) relationship is reflected in this technique, which provides opportunities for creative developments in additive manufacturing. From material design to structural design, data-driven models play a crucial role in examining the enormous design space in additive manufacturing.
In this case study, PLA was utilized as a raw material for 3D printing in the biomedical field. PLA composites were developed and used to fabricate customized implants for bone repair, tissue engineering scaffolds, and drug delivery systems [30, 104]. The integration of PLA in biomedical applications is supported by its impressive technical data. PLA offers high tensile strength, biocompatibility, and ease of sterilization, making it an ideal choice for producing medical implants and devices. Additionally, its transparency and the ability to degrade over time make it suitable for applications where monitoring or controlled degradation is required. These technical attributes have contributed to the successful utilization of PLA in biomedical settings, opening new possibilities for advancements in medical technology [104]. PLA has become a leading bio-based polymer for 3D printing, marked by advancements like its widespread adoption and the superior performance of PLA-graphene composites in surface texture, tensile, and flexural stress [105].
The emergence of 4D printing defined as 3D printing with the ability to alter a structural property or functionality over time has sparked widespread excitement across various domains, revealing a plethora of applications utilizing diverse printing techniques, materials, and activation mechanisms. Biomedical engineering has emerged as a key area of interest for 4D printing advancements. Notably, the use of PLA, a cost-effective and biodegradable polymer, has led to significant strides in this technology, signaling promising avenues for future innovation in 4D printing [106]. The advancement of 4D printing is shown in Fig. 12.
Fig. 12
The prospective uses of 4D printing technology with PLA polymer [106]
Environmental and economic implications
NFPCs offer significant environmental and economic benefits. including carbon footprints reduction, mitigating plastic pollution and thus supporting the circular economy [107]. These composites also promote resource efficiency by utilizing agricultural by-products and consuming less energy during production. Economically, natural fibers are cost-effective, support rural development by providing farmers with additional income, and meet the growing demand for sustainable materials across various industries. Market growth is driven by industries such as automotive, construction, and packaging, while innovation in these composites enhances competitiveness and opens up new applications [108, 109].
The global environment has prompted the development of commodity plastics made from environmentally degradable polymers. This transition to environmentally friendly plastics, such as PLA-based materials, has significant environmental and economic implications. PLA materials offer numerous advantages in terms of their environmental impact and economic feasibility. Firstly, PLA is derived from renewable resources, such as corn and sugarcane, making it a more sustainable alternative to petrochemical-based polymers. Additionally, PLA is biodegradable, recyclable, and compostable, further reducing its environmental footprint. Furthermore, the production of PLA consumes carbon dioxide, helping to mitigate greenhouse gas emissions [110]. On the economic front, PLA materials can contribute to job creation and economic growth. For instance, the production of PLA requires a consistent supply of biomass feedstocks, which can support agriculture and farming industries. Moreover, the versatility of PLA-based plastics allows them to be used in a wide range of applications, including packaging, textiles, automotive components, and medical devices. This diversification of PLA applications can lead to increased market demand and potential economic benefits. The use of PLA materials has significant environmental and economic implications. PLA materials offer numerous advantages in terms of their environmental impact and economic feasibility [30, 42]. Overall, the adoption of PLA materials can contribute to a more sustainable and circular economy, reducing dependence on fossil fuels and minimizing plastic waste accumulation in the environment. Consequently, the widespread use of PLA materials can potentially mitigate environmental pollution caused by traditional plastics while benefiting society through their versatility and economic potential. The application of PLA materials has significant environmental and economic implications. The environmental, sustainable, and low carbon footprint of NFP and PLA is depicted in Fig. 13.
Fig. 13
Environmentally sustainable impact of NFP and PLA material
PLA can be readily processed using extrusion, injection molding, casting, thermoforming, compounding, 3D printing, and fiber spinning. Additionally, biobased carbon from PLA can be integrated into durable products. Using renewable carbon in durable plastics reduces dependency on petroleum resources, potentially saving numerous barrels of oil annually. PLA-based products can be subjected to chemical recycling, a depolymerization process using chemicals such as solvents or acids. Therefore, enhancing PLA properties is crucial for expanding its use in high-performance applications [28].
Challenges and future directions
In the context of Natural Fibre Polymer Composites (NFPCs) and PLA composites, the integration of AI and ML is prepared to shape a transformative future. AI-powered predictive modelling, powered by deep learning and extensive datasets, will revolutionize material development by accurately projecting mechanical, thermal, and environmental properties, expediting the design process and minimizing trial-and-error iterations. Concurrently, real-time monitoring and control systems, underpinned by AI, will ensure manufacturing precision, enabling dynamic adjustments and consistent quality across NFPCs and PLA composites. Digital twins will emerge as invaluable tools for simulating the entire lifecycle of these materials, offering insights for optimization, maintenance, and sustainability. Sustainable development will be paramount, guided by AI-driven life cycle analyses to enhance environmental assessments and steer material choices towards eco-conscious alternatives. Material innovation will reach new heights as AI explores intricate design spaces, yielding composites with tailored properties and multifunctionality. Collaboration will flourish through open data platforms, promoting transparency and accelerating collective progress, while AI-guided material discovery will uncover novel combinations, pushing the boundaries of performance and sustainability. Together, these advancements herald a future where NFPCs and PLA composites meet and exceed the demands of diverse applications, paving the way for a more sustainable and technologically advanced world. Challenges and future directions of PLA materials include improving their mechanical properties, enhancing their heat resistance, exploring new additive manufacturing techniques, such as multi-material printing and continuous fiber reinforcement, and finding sustainable alternatives to their production methods.
Furthermore, research efforts are focused on reducing material degradation and improving the long-term durability of these materials [44]. In addition, the development of recycling and waste management strategies for these materials is crucial to minimize their environmental impact. Challenges and future directions of NFP and PLA, materials include improving their mechanical properties, enhancing their heat resistance, exploring new additive manufacturing techniques such as multi-material printing and continuous fiber reinforcement, and finding sustainable alternatives to their production methods. Furthermore, research efforts are focused on reducing material degradation and improving the long-term durability of these materials [43].
The future of AI and ML in Natural Fibre Polymer Composites (NFPCs) is set to revolutionize the field by significantly enhancing various aspects of material development and application. Advanced predictive modelling will allow for accurate forecasts of mechanical, thermal, and environmental properties of composites, leveraging deep learning and large datasets to streamline the traditionally labour-intensive trial-and-error process. Process optimization will see the rise of intelligent manufacturing systems capable of real-time monitoring and control, utilizing sensor data and ML algorithms to detect anomalies, predict defects, and adjust processing parameters dynamically, ensuring consistent quality. The concept of digital twins, which are virtual replicas of physical systems, will enable comprehensive simulations of the lifecycle of NFPCs, from manufacturing to end-use, providing valuable insights for optimizing performance and maintenance.
Sustainable development will be a critical focus, with AI enhancing the accuracy and efficiency of life cycle analysis (LCA) to comprehensively assess environmental impacts. AI models will also be developed to predict and improve the biodegradability and recyclability of NFPCs and PLA, guiding the design of composites that meet performance standards while minimizing environmental impact. Material innovation will benefit from AI-driven genetic algorithms and evolutionary computation, which will explore vast design spaces at micro and nano levels to create materials with superior, tailored properties. The development of multifunctional composites, combining structural performance with additional functionalities like self-healing, sensing, and energy storage, will be accelerated by AI's ability to identify optimal fiber, matrix, and additive combinations. Data-driven research and collaboration will be bolstered by the establishment of open data platforms, facilitating the sharing of datasets and AI models, which in turn will expedite innovation. Standardization and benchmarking of data collection and reporting methods will ensure consistency and reliability in AI predictions, promoting wider adoption in the industry. AI's capability for exploratory data analysis will uncover hidden patterns and correlations in experimental data, leading to the discovery of novel natural fibers and matrix combinations with enhanced properties. Automated experimentation platforms integrated with AI will design and interpret experiments more efficiently, iteratively refining hypotheses and accelerating breakthroughs in material science. These advancements will collectively lead to the development of more efficient, sustainable, and innovative NFPCs, meeting the growing demand for high-performance, environmentally friendly materials in various applications.
Conclusion
The integration of AI and ML techniques in NFP and PLA composites has revolutionized the development of eco-friendly and sustainable materials. This integration has not only advanced material synthesis and technology advancement but also opened up new avenues for paving way the existing complexities in polymer fiber technology towards sustainability. This article summarizes and showcases the potential in optimizing material properties, manufacturing processes through advanced AI and ML integration. the cutting-edge technologies with the integration of advanced intelligence towards developing the next-generation composite materials with enhanced performance and eco-friendly characteristics are the given priorities by the industrial and commercial practitioners as footsteps of continued global green sustainability.
Acknowledgements
The authors extend their appreciation to the Deanship of Scientific Research at King Khalid University, Abha, Kingdom of Saudi Arabia for funding this work through small research Groups RGP.1/214/45.
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Conflicts of interest
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Advances in natural fiber polymer and PLA composites through artificial intelligence and machine learning integration
Authors
Md. Helal Uddin Mohammed Huzaifa Mulla Tarek Abedin Abreeza Manap Boon Kar Yap Reji Kumar Rajamony Kiran Shahapurkar T. M. Yunus Khan Manzoore Elahi M. Soudagar Mohammad Nur-E-Alam