In modern day structural engineering, fiber-composites play vital role in various industries for light-weight constructions. These structures can also be equipped with multi-component sensor systems for various performance evaluations both during and post curing processes.  In this work a novel method is developed to place a wireless sensor inside a fiber reinforced composite system to enable multifunctionality without much trade-off in mechanical performance. The aim of such system is to both observe curing kinetics during the curing process and to support the structure after curing by sensing stress concentration (post-curing) during dynamic loading process.
Key objective here was to optimize the sensor shape to minimize stress accumulation and crack propagation around the sensor geometry inside the cured composite sample under stress. A finite element simulation model is developed for this purpose and a parametric model for the sensor geometry provided better insight into the force distribution along the fibers around the sensor element. Mechanical performance of fiber composites equipped with sensor samples, which are extended by dielectric channels, were analyzed. Such channels facilitate transmission of sensor information through electrically conductive elements such as carbon fibers, which are widespread in today’s industrial and consumer applications.
Consequently, different testing sample combinations were prepared, for which, fibers were either cut or bend around the sensors and dielectric channels. These modifications, results in a decrease in mechanical characteristics in the fiber composites and in this work a detailed comparison is made between different methodologies of sensor placement, in vacuum assisted resin infusion (VARI) process. The samples were tested under different standard loading conditions and the results were compared with simulation model to produce a reliable correlation. Eventually, the goal of this work is to train the system in VARI and transport the knowledge into various industrial standard manufacturing processes like press-forming, autoclave curing etc.