<p>The rapid evolution of autonomous aerospace and robotic platforms has intensified the need for structural systems that can maintain performance after damage while remaining lightweight and adaptable. Traditional self-healing polymers and composites have provided beneficial recovery of mechanical properties, but they often struggle to meet the stringent requirements of advanced missions, such as multi-cycle healing, resistance to extreme operating conditions, and integration with additional functions like electromagnetic control. To address these limitations, a growing body of research is now focused on self-healing metastructures—engineered architectures that combine healing capability with mechanical, thermal, and electromagnetic functionalities. Architected designs such as bioinspired hierarchical structures, triply periodic minimal surfaces, and programmable lattice networks allow healing pathways to be incorporated directly into the load-bearing framework, enabling structural recovery without sacrificing stiffness or stealth performance. Although recent progress demonstrates promising mechanical recovery and multifunctional behaviour, most available studies remain at lab-scale. Healing speed, multi-cycle durability, and field-environment stability still need deeper validation before full aerospace deployment. This review provides a technical assessment of material strategies, fabrication approaches, and functional integration routes that support the development of such metastructures for aerospace and robotic applications. By linking healing mechanisms with architectural design and mission-oriented performance metrics, this work identifies the unique advantages of metastructures over conventional self-healing materials and proposes a forward-looking strategy to accelerate their adoption in systems where endurance, reliability, and multifunctionality are essential.</p>

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Advances in self-healing architected materials for flight structures: multifunctional performance and technology transition challenges

  • Ali Imran Ansari,
  • Nazir Ahmad Sheikh,
  • Mohammad Mursaleen

摘要

The rapid evolution of autonomous aerospace and robotic platforms has intensified the need for structural systems that can maintain performance after damage while remaining lightweight and adaptable. Traditional self-healing polymers and composites have provided beneficial recovery of mechanical properties, but they often struggle to meet the stringent requirements of advanced missions, such as multi-cycle healing, resistance to extreme operating conditions, and integration with additional functions like electromagnetic control. To address these limitations, a growing body of research is now focused on self-healing metastructures—engineered architectures that combine healing capability with mechanical, thermal, and electromagnetic functionalities. Architected designs such as bioinspired hierarchical structures, triply periodic minimal surfaces, and programmable lattice networks allow healing pathways to be incorporated directly into the load-bearing framework, enabling structural recovery without sacrificing stiffness or stealth performance. Although recent progress demonstrates promising mechanical recovery and multifunctional behaviour, most available studies remain at lab-scale. Healing speed, multi-cycle durability, and field-environment stability still need deeper validation before full aerospace deployment. This review provides a technical assessment of material strategies, fabrication approaches, and functional integration routes that support the development of such metastructures for aerospace and robotic applications. By linking healing mechanisms with architectural design and mission-oriented performance metrics, this work identifies the unique advantages of metastructures over conventional self-healing materials and proposes a forward-looking strategy to accelerate their adoption in systems where endurance, reliability, and multifunctionality are essential.