SNU Develops Ultralight Carbon Fiber Lattice Structures With Aluminum-Level Performance
BY Composights
Published: 15 May 2026
Share :
Researchers at Seoul National University (SNU) have developed mesoscale carbon fiber lattice structures capable of delivering aluminum-level mechanical performance while weighing as little as one-hundredth the weight of aluminum. The work was led by Prof. Sung-Hoon Ahn s research team in the Department of Mechanical Engineering.
The structures are manufactured using a fabrication approach called 3D node winding, which enables a single continuous carbon fiber to form complex three-dimensional lattice geometries without joints or layered assembly. The process differs from conventional composite manufacturing methods that rely on stacked laminates or assembled components, which can introduce weak interfaces and limit structural design freedom.
According to the research team, the developed carbon fiber composite lattices achieve compressive strengths of approximately 10-30 MPa while maintaining extremely low mass. On a strength-to-weight basis, the structures can reach aluminum-level efficiency at only 1/40 to 1/100 of aluminum s weight. At equivalent weight, the lattice structures were reported to be up to 10 times stronger than conventional lattice configurations.
To validate the concept in a practical application, the researchers integrated the structures into a drone frame. Testing showed that the redesigned composite frame reduced structural weight by approximately 79%, resulting in a 33% increase in flight time under the same operating conditions.
The fabrication method uses a temporary support structure to define nodal geometry before a continuous carbon fiber is wound through the system to create a spatial lattice network. Resin impregnation is then applied to consolidate the structure into a load-bearing composite component. Because the fiber path remains continuous throughout the structure, force transfer occurs without the stress concentrations commonly associated with joints and bonded interfaces.
The research was published in Nature Communications under the title Mesoscale carbon fiber lattices with foam-like weight and bulk strength. The team stated that the approach could support future lightweight structural applications in drones, robotics, aerospace systems, mobility platforms, and other engineered load-bearing structures where mass reduction and structural efficiency are critical.
Source : Seoul National University | Research
