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Advanced Materials Lab

Materials Technologies - Company

The laboratory, under the supervision of Dr. Abhishek Kumar, conducts disruptive research on advanced materials and processes—from computational modelling to multifunctional materials and advanced manufacturing—for multidomain applications, with a strong emphasis on sustainable approaches. It also plays an active role in several national and international civil and defense projects and are actively involved in the definition of strategic research and innovation agenda in European initiatives such as IAM-I and CHIPS JU.

Computational material modelling

Computational material modelling

 

The research cluster, coordinated by Dr. Federico Danzi, focuses on the development of multiscale and high-fidelity finite element models of complex materials and composites, supporting design, certification, validation and verification across multiple domains (land, air, naval and space). Our research approach integrates open source and commercial simulation tools with custom and calibrated constitutive models and statistical variability, and follows the entire modelling lifecycle, from experimental characterization of materials, through numerical simulation, to experimental benchmarking and validation of the results.

What we do

  • Simulation and validation of high-velocity impact scenarios in multidomain, such as ballistic armor impacts and bird-strike events.
  • Hybrid experimental-virtual approaches for the estimation of material allowables, uncertainty quantification and propagation using advanced AI algorithms.
  • Calibration & validation of material models, enabling accurate representation of complex non-linear behavior including plasticity, damage, temperature and strain-rate.
  • Workflow development for atomistic material discovery and micromechanical modeling.

Multifunctional Materials

 

The research cluster, coordinated by Dr. Muhammad Zahid, focuses on the development and integration of diverse classes of materials for future aerospace and defense technologies. The main focus is on disruptive energy harvesting and storage devices, and nanomaterials to exploit their full potential across demanding environments.

What we do

  • Integration of nanomaterials such as graphene, hBN, MXenes, metals, ceramics, etc., to develop smart solutions for applications in thermal management, sensing, de-icing, EMI shielding and printed electronics, etc.
  • Development and optimization of innovative photovoltaics for aerospace applications, such as perovskite solar cells.
  • Study of advanced materials for next generation batteries (e.g. solid state, Li-S, etc.) capable of operating in extreme environments.

Advanced Manufacturing

 

The research cluster, coordinated by Dr. Sara Varetti, focuses on the study, development and optimization of innovative processes. The aim is to enhance the performance of components, efficiency and sustainability of processes, and enabling the workability of new materials. The team of researchers works towards cutting-edge technologies integrating automation, artificial intelligence and smart manufacturing beyond the state of the art, providing reliable and disruptive manufacturing solutions.

What we do

  • Optimization and real time monitoring of manufacturing processes, such as Additive Manufacturing, Out of Autoclave (OOA), multi-material joining, In-Space Manufacturing, ISRU etc.
  • Studying advanced recycling processes, Life Cycle Assessment (LCA) methodologies and novel materials composition (e.g. vitrimers, metal alloys, adhesives) to reduce dependence on Critical Raw Materials (CRMs).
  • Acceleration of materials and process development with a focus on developing Self-Driving Laboratories. This approach integrates robotics, automated experimentation platforms, advanced sensor networks, and AI-driven optimization algorithms.

Results

5

Patents submitted/published

7 (6 running)

PhD students

2 (1 running)

Master thesis

2025 conference contributions

  • CFRAC 2025 - International Conference on Computational Modeling of Fracture and Failure of Materials and Structures, 2025 - Uncertainity Quantification of Open-Hole coupons through a global-local approach with PC-Kriging surrogate modelling
  • COMPTEST2025 - 12th International Conference on Composites Testing and Model Identification, 2025: Sparse sensor placement optimization technique for delamination detection in composite panels
  • ICSS2025 International Conference on Sandwich Structures - Numerical modelling of interface delamination in sandwich composite structures
  • DCE2025 - Doctoral Congress in Engineering: Research perspectives in the aerospace and defence field.
  • Varetti, L. Margaria, A. Coluccia, G. De Pasquale, A. De Zanet, E. Pappa, A. Kumar, M. Cabrioli and M. Vanazzi (2025). Fatigue characterization of AlSi10Mg alloy from variable L-PBF processing parameters addressed to hybrid joints of aerostructures. EURO PM 2025.
  • Varetti, A. De Zanet, E. Pappa, C. Annicchiarico, A., N. Gallo, M. Cabrioli, M. Vanazzi, F.E. Altunok, B. Destito and G. De Pasquale (2025). AlSi10mg additively manufactured anchors for a novel multimaterial hybrid joining for aerospace. Sampe Europe 2025.
  • Cabrioli, M. Silva Colmenero, M. Vanazzi, S. Varetti, A. Kumar, L. Margaria, G. De Pasquale, J. Bellver, B. Perez (2025). Upcycling AlSi10Mg scrap metal from multi-material joints through atomization and generation of aerospace-grade metal powders. EURO PM 2025.
  • Montecucco, A. Kumar, M. Dispenza (2025). Data Driven Tuning Of Perovskite Photovoltaics For Space Applications, PVSpace-25, New Generation Photovoltaics for Space
  • Pappa, A. Kumar, F. Danzi, A. Campilungo, C. Annicchiarico, N. Gallo, M. Cabrioli, M. S. Colmenero, M. Vanazzi, B. Fošnarič, T. Černelič, V. Capitani, S. Pasquino, L. Margaria, F. Enes Altunok, A. Coluccia, G. De Pasquale, "Joining technologies combining CFRPs and 3D metal anchors for aeronautical structural parts: case study - vertical stabilizer", Society for the Advancement of Material and Process Engineering Conf. (SAMPE EUROPE), Amsterdam (2025).
  • Pappa, A. Kumar, C. Annicchiarico, N. Gallo, M. Cabrioli , M. S. Colmenero, M. Vanazzi, B. Fošnarič, T. Černelič, L. Margaria, F. Enes Altunok, A. Coluccia, G. De Pasquale. "Sustainable aviation through a novel multi-material joint technology for aeronautical applications", 15th European Aerospace Science Network Int. Conf. (EASN), Madrid (2025).
  • ICEPFE2025: 15th International Conference & Exhibition on Green Flexible Printed Electronics Industry: Toward Circular Sensing: Reusable Printed Sensor Technologies and Sustainable Materials Innovations in the EECONE Project
  • A. Vijayakumar, M. Zahid, S. G. Corvaglia, F. Lionetto, A. Maffezzoli. Mode I Characterisation of Skin/Core Adhesion of Sandwich Panels Obtained by Ultrasonic Welding. Comptest 2025 – 11th International Conference on Composite Testing and Model Identification, Riga, Latvia, June 2025.
  • A. Vijayakumar, M. Zahid, S. G. Corvaglia, F. Lionetto, A. Maffezzoli. Skin/Core Bonding in Sandwich Panels by Ultrasonic Welding: Processing and Performances. SAMPE Europe Conference 2025, Amsterdam, Netherlands, October 2025.
  • SIE 2025 - Annual Meeting of the Italian Society of Electronics. Fabrication and Analysis of Graphite Nanoplatelet-Doped Epoxy Strain Sensors.
  • MetroAeroSpace 2025 - International Workshop on Metrology for Aerospace, Development and characterization of graphene nanoplatelet-based strain sensors for structural health monitoring.
  • EUROSENSORS 2025 - European Conference on Solid-State Transducers. GNPs-Based Strain Sensors Derived from Recycled Cellulose Acetate: Fabrication and Analysis. 
     

Media coverage

Funded projects (current and concluded)

EC Project EuroQCI GROUND SEGMENT – OQTAVO
Horizon EU EECONE
Topic:
European ECOsystem for greeN Electronics

 
PNRR DAMAS
Topic:
Digital innovation hub for Automotive and AeroSpace 
DIGITAL EUROPE QUID
Horizon EU MIMOSA
Topic:
Multimaterial airframes based on 3D joints between additively manufactured metals and carbon-fiber composites.
 
DIGITAL EUROPE QUID
Horizon EU EuroFMX
Topic: European TrUstworthy GeneRative AI & AutonOmisation Frontier Models for Manufacturing-X Competitiveness
 
European Defense Fund ECOBALLIFE
Topic:
Research in eco-designed ballistic systems for durable lightweight protections against current and new threats in platform and personal applications.
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