Researchers at Texas A&M University have unveiled the remarkable properties of a smart plastic that can heal itself, retain its shape, and be recycled, marking a significant advancement for the aerospace, defense, and automotive industries. The material, a carbon-fiber composite called Aromatic Thermosetting Copolyester, or ATSP, was the focus of two recent studies published in the journals Macromolecules and the Journal of Composite Materials. Led by aerospace engineering professor Dr. Mohammad Naraghi, the team investigated the material’s mechanical properties and its unique ability to repair damage on demand, potentially revolutionizing the design and maintenance of high-performance products.

ATSP belongs to an emerging class of materials known as vitrimers. These materials uniquely combine the qualities of two common types of plastics: the flexibility and recyclability of thermoplastics, which soften when heated, and the strength and chemical stability of thermosets, which are permanently hardened. What makes vitrimers special is their internal network of chemical bonds that can break and reform when heated. This “bond exchange” mechanism is the key to ATSP’s two primary abilities. The first is shape recovery, where the material can return to its original form, and the second is self-healing, where it can mend cracks and discontinuities.

To test these properties, the research team conducted several rigorous experiments. In one study, they used a method called cyclical creep testing to identify the material’s vitrification temperature—the point at which bond exchanges become active enough to cause healing. By periodically heating the material to 160 degrees Celsius during a fatigue test, they extended its life from 160 stress cycles to over 500. Remarkably, the material grew more durable during the healing process. In another experiment, the team subjected the composite to five cycles of fracture and then healing at 280 degrees Celsius. The material demonstrated complete healing after the first two cycles and retained approximately 80% healing efficiency by the fifth, indicating robust performance even after repeated, significant damage.

These findings highlight the potential of ATSP to create products that are not only stronger and lighter than traditional materials, such as steel and aluminum, but also more sustainable and reliable. In the automotive sector, this could lead to vehicles that can repair dents and deformations after a collision, significantly improving safety. For aerospace, it means aircraft parts could heal in-flight damage, preventing catastrophic failure. Furthermore, because vitrimers can be crushed and remolded multiple times without degradation, ATSP offers a durable and environmentally friendly alternative to conventional plastics, paving the way for a future where materials not only endure but also evolve.

References

• Elayyan, Z. & Texas A&M University. (2025, August 11). Carbon-fiber smart plastic: Self-healing, shape-shifting and stronger than steel. Tech Xplore; Texas A&M University. https://techxplore.com/news/2025-08-carbon-fiber-smart-plastic-shifting.html

• Mandal, T., Ozten, U., Ghanbarian, M., Rahavi, S., & Naraghi, M. (2025). Identifying the origin of intrinsic self-healing gradual decay in vitrimer carbon fiber reinforced polymer composites. Journal of Composite Materials, 00219983251362394. https://doi.org/10.1177/00219983251362394

• Vaught, L. O., Naraghi, M., Meyer, J. L., & Polycarpou, A. A. (2025). Shape memory and fatigue reversal in a covalent adaptive network polymer below glass transition temperature. Macromolecules, 58(8), 3916–3923. https://doi.org/10.1021/acs.macromol.4c02376