Successful Localization of 'Ultralightweight and Recyclable' New Material for Air Taxis

KIST "52% Lighter Than Existing Materials and 27% Increase in Flight Time"

The government and industry have received a green light for the localization of 'air taxis,' which are being actively developed as future transportation means. Domestic researchers have succeeded in localizing a new material that is lightweight, strong, and recyclable, suitable for use in the body and frame of urban air mobility (UAM).

On April 19, 2023, SK Telecom's UAM was exhibited at the '2023 World IT Show' held at COEX in Gangnam-gu, Seoul. Photo by Jinhyung Kang aymsdream@

The Korea Institute of Science and Technology (KIST) announced on the 2nd that Dr. Kim Jae-woo of the Electromagnetic Wave Solution Convergence Research Group, together with Professor Kim Sung-hoon of Hanyang University and Professor Kim Sung-ryun of Jeonbuk National University, succeeded in developing a 100% self-reinforced composite material using only one type of polypropylene (PP) polymer.

For future mobility means such as urban air mobility (UAM) to become a reality, fuel efficiency must be increased while reducing carbon emissions. To achieve this, the development of new materials with excellent physical properties and recyclability is essential. Self-reinforced composites (RC) are inexpensive and lightweight. Since the reinforcement and matrix are composed of the same components, they offer advantages in disposal and recycling. For this reason, they are attracting attention as next-generation composite materials to replace carbon fiber-reinforced composites used in aircraft and other applications.

Schematic diagram of 100% self-reinforced composite manufacturing process and application. Image source: Provided by KIST.

The problem has been that, until now, to improve fluidity and impregnation when manufacturing self-reinforced composites, chemically different components were mixed into either the reinforcement or the matrix, resulting in reduced physical properties and recyclability. The research team succeeded in controlling the melting point, fluidity, and impregnation by adjusting the chain structure of the polypropylene matrix through a four-axis extrusion process. The developed self-reinforced composite achieved the highest level of mechanical properties, with adhesion strength, tensile strength, and impact resistance improved by 333%, 228%, and 2700%, respectively, compared to previous studies. When applied as a frame material for small drones, the material was 52% lighter than conventional carbon fiber-reinforced composites, and flight time increased by 27%, confirming its potential for next-generation mobility applications.

Dr. Kim Jae-woo of KIST (co-first author) said, “The 100% self-reinforced composite engineering process developed this time can be immediately applied in the industry. We will continuously cooperate with the industry to secure the global competitiveness of self-reinforced composites.”

The research results were published in the latest issue of the international journal in the field of chemical engineering, ‘Chemical Engineering Journal’ (IF:16.744, top 2.448% in JCR category).

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