A Comprehensive Review of Composite Materials: Current and Future Prospects in Aerospace Applications

ABSTRACT The aerospace sector continually demands advanced, multifunctional materials capable of enhancing performance, reducing structural weight, and improving fuel efficiency while ensuring exceptional integrity, durability, safety, and environmental sustainability. The inherent limitations of conventional metallic and monolithic materials in aircraft manufacturing, such as high density, corrosion susceptibility, and limited fatigue resistance, have accelerated the adoption of composite materials as transformative alternatives. This review provides a comprehensive assessment of the properties, advantages, and applications of diverse aerospace composites, with emphasis on fiber‐reinforced Polymer Composites, hybrid composites, and advanced functional materials, including nano‐ and bio‐composites. The discussion extends to their deployment across critical aircraft components and their potential to replace heavier, costlier, and technologically outdated materials. Conventional manufacturing challenges, such as inadequate heat dissipation, weight penalties, and microstructural non‐uniformity, are critically examined, alongside emerging processing methods that address these limitations. Recent technological advancements and operational case studies are presented to illustrate the practical integration of next‐generation composites in modern aerospace systems. By synthesizing current literature, this work outlines the pathways through which advanced composites can redefine aerospace engineering, enabling the production of lighter, stronger, and more cost‐efficient aircraft, thereby supporting the industry's progression toward superior performance and sustainable innovation.