OPTIVEIL®: Enabling Smart, Multifunctional Composites

A new publication from the School of Engineering and Materials Science, Queen Mary University of London and WMG, University of Warwick, has demonstrated the multifunctional potential of OPTIVEIL®, the recycled carbon fibre veil from James Cropper Advanced Materials, in the manufacture of natural fibre composites. Originally developed to enhance surface quality, OPTIVEIL® is shown here to play a far more dynamic role, enabling real-time process monitoring, embedded structural health diagnostics and significantly, low-energy out-of-oven (OoO) resin curing. All made possible through the veil’s inherent electrical conductivity.

Energy-Efficient Curing Through Joule Heating

One of the key outcomes of the study is the use of OPTIVEIL® as a surface-integrated heating element.

By applying a low electrical voltage across the veil, researchers generated heat directly within the composite lay-up, a process known as Joule heating. This heat was then used to cure the thermoset resin, eliminating the need for traditional oven-based curing.

The results:

    Over 95% reduction in energy consumption
    Faster, more targeted curing
    A streamlined manufacturing process with lower emissions

This approach allows manufacturers to rethink traditional composite processing methods, with energy savings that support both commercial efficiency and sustainability targets.

One Veil, Multiple Functions

The study also demonstrated that OPTIVEIL® delivers added functionality throughout the composite lifecycle:

During manufacture – OPTIVEIL®’s conductivity enabled real-time monitoring of resin flow, supporting better control and consistency in infusion.
During cure, it served as the heat source, reducing energy demand and avoiding bulky external equipment.
In service, the same conductive network allowed for structural health monitoring through Electrical Impedance Tomography (EIT), detecting damage without invasive inspection.

All achieved with a single, lightweight, surface-applied nonwoven.

Sustainable Materials, Smarter Manufacturing

Manufactured from recycled carbon fibre, OPTIVEIL® embodies James Cropper’s commitment to material circularity and innovation. In the study, it was paired with a natural flax reinforcement to create a composite that was not only smart and functional but environmentally considered from the outset.

This upcycling of advanced fibre waste into high-performance, value-adding applications demonstrates how functionality and sustainability can coexist within industrial materials.

Dr. Han Zhang

Reader in Multifunctional Polymers and Composites at WMG, University of Warwick

“ We are pleased to demonstrate how recycled carbon fibre veils such as OPTIVEIL® can enable energy-efficient, multifunctional composites. This work highlights the wider potential of reclaimed fibre technologies to add real value in sustainable and intelligent manufacturing applications. ”

Dr. Han Zhang

Reader in Multifunctional Polymers and Composites at WMG, University of Warwick

In Summary

 OPTIVEIL® James Cropper’s recycled carbon fibre veil, enabled real-time process monitoring, out-of-oven curing via Joule heating, and non-destructive structural health diagnostics.
This single layer delivered more than 95% energy savings during resin cure, without compromising performance.
The veil’s multifunctionality helps unlock simplified, smarter and lower-carbon composite systems.