Researchers at the Chinese Academy of Sciences have proposed a new way to manufacture composite materials for drones, aircraft, and rockets, challenging six decades of conventional methods.
A research team at the Institute of Mechanics under the Chinese Academy of Sciences has developed a new composite material manufacturing method it claims improves the strength and reliability of aerospace structures by up to 26%. The institute announced the findings on March 9, 2026.
The method advances what engineers call the “balanced lay-up” approach. This is a technique for stacking fibre layers symmetrically and at opposing angles to reduce internal stresses within the material. The team’s updated version of this method also achieved a 13% improvement in joint performance. On top of the strength gains, the process reduces curing deformation during manufacturing. Curing deformation is a known source of defects in composite production, where materials warp or distort as they harden under heat and pressure.
Lower deformation translates directly to greater design flexibility. When composite parts come out of the manufacturing process with fewer distortions, engineers have more freedom to work with complex, high-precision components. The institute stated this is especially relevant for parts like fuselages, wings, and load-bearing panels used in aircraft, drones, and rockets.
Composite materials are central to modern aerospace. They combine light weight with high strength, making them essential for structures where every gram matters. Carbon fibre composites make up over 50% of the structural weight of aircraft like the Boeing 787 and Airbus A350.
According to MarketsandMarkets, the global aerospace composites market is expected to reach $53.4 billion by 2030, up from $30.3 billion in 2025, growing at a 12% annual rate. SNS Insider projects the market will hit $109.14 billion by 2035. Carbon fibre reinforced polymers dominate the sector, holding roughly 63% of overall revenue, according to Roots Analysis. Aerospace composites reduce structural weight by up to 25% compared to aluminum, according to OpenPR, lowering fuel consumption per flight and helping airlines meet tightening emissions targets.
The conventional balanced lay-up method has been the standard approach to composite manufacturing for roughly 60 years. The Chinese team’s modification is the first reported advance in this specific technique to produce measurable gains in both strength and manufacturing quality at the same time. The hand lay-up process remains one of several methods used across the industry, alongside automated fibre placement and resin transfer moulding, according to Allied Market Research.
The research is part of a broader push by China to develop advanced materials for its growing aerospace and defense sectors. China’s drone industry has also expanded rapidly in both civilian and military applications, with composite materials playing a key role in keeping airframes light and durable for extended flight times.
The institute did not disclose whether the method is already being applied in production or remains at the research stage. No commercial or military programs were named in connection with the findings.
