Engineering integration of graphene aerogels in aerospace mechanics current state of research and future application

Graphene aerogel is an ultralight material with outstanding thermal, electrical, and mechanical properties, which positions it as a promising candidate for advanced aerospace engineering applications. Recent advances in additive manufacturing, including three-dimensional printing and bio-inspired fabrication strategies, have enabled the design of architected graphene aerogel structures that draw on hierarchical and cellular architectures found in natural systems. By translating biological structural principles into engineered materials, bio-inspired design allows precise control over porosity, load transfer, and functional grading, thereby enhancing strength-to-weight ratios, energy dissipation, and multifunctional integration, all of which are critical requirements for aerospace structures. This review examines the convergence of graphene aerogel research with these advanced fabrication approaches, highlighting their implications for structural efficiency, weight reduction, and the integration of sensing and electromagnetic interference (EMI) shielding functionalities. Despite persistent challenges related to mechanical fragility under extreme loading conditions, energy-intensive production routes, and scalability constraints, reported properties such as ultra-low densities as low as 3.13 mg/cm3 and EMI shielding effectiveness of up to 87 dB at a thickness of 2.0 mm underscore the technological relevance of graphene aerogels. By synthesizing current literature and identifying key knowledge gaps, this work outlines critical research pathways grounded in bio-inspired design principles to advance the application of graphene aerogels in future aerospace structures.