Conductive Ink Technologies and Computational Modeling for Aerospace Structural Health Monitoring: A Comprehensive Review

Abstract

Conductive ink technologies have emerged as a transformative solution in aerospace engineering, enabling the development of lightweight, flexible, and cost-effective sensing systems for structural health monitoring (SHM). The increasing demand for real-time, reliable monitoring under harsh operational conditions necessitates the integration of advanced materials and computational techniques. This review aims to provide a comprehensive overview of recent developments in conductive ink formulations, printing technologies, and their integration with computational modeling, particularly computational fluid dynamics (CFD), for aerospace SHM applications. A systematic literature review approach, guided by PRISMA methodology, was employed to analyze relevant studies on metal-based, carbon-based, and hybrid conductive inks, as well as their deposition processes and performance characteristics. The findings indicate that conductive inks, especially hybrid formulations, offer significant advantages in terms of conductivity, flexibility, and environmental resistance, although challenges related to adhesion, stability, and scalability persist. Furthermore, computational modeling, including CFD and multiphysics approaches, plays a critical role in optimizing ink deposition, improving print quality, and enhancing predictive maintenance capabilities when integrated with SHM systems. The review also identifies key research gaps, particularly the limited real-time integration of computational models with SHM frameworks and the need for standardized validation protocols. The study highlights the potential of combining conductive ink technologies with advanced computational methods to advance predictive maintenance strategies and improve safety, efficiency, and sustainability in aerospace applications, while also offering opportunities for cross-disciplinary applications in emerging fields.