Advanced Fiber Paper-Based Functional Materials: From Fiber Engineering, Wet-Forming Mechanism, and Structure–Function Integration to Emerging Applications

Abstract

Advanced fiber paper-based functional materials (AFPFMs) are manufactured from aramid fibers, polyimide fibers, carbon fibers and inorganic high-performance fibers through wet-laid forming, which have overcome the inherent performance limitations of conventional plant fiber paper. These porous sheet composites serve as strategic core materials for aerospace, rail transit, national defense, and new energy sectors, arousing growing global research interest. Distinct from traditional papermaking, AFPFM manufacturing relies on an integrated technical chain covering fiber modification, slurry tuning, forming regulation, and post-treatment; yet, it confronts a series of fundamental and engineering challenges. This review first elaborates core wet-forming theories, and systematically clarifies intrinsic correlations between fiber morphology manipulation, surface functionalization, slurry rheology and macro-micro paper performances. Four representative AFPFM systems are then discussed to summarize their structure–function design principles and practical application scenarios. Furthermore, a multi-dimensional evaluation framework for fiber slurries and final paper products is established. Critical industrialization barriers are highlighted, including inconsistent batch quality, insufficient precision fabrication and weak translation from laboratory findings to large-scale production. By constructing a full-spectrum analytical system spanning fiber raw materials to advanced functional applications, this review offers a holistic theoretical and technical reference for relevant researchers and industrial practitioners.

Graphical Abstract

Keywords

Advanced fibers / Paper-based functional materials / Wet-forming / Structure–function integration / Porous structure

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Funding

The National Natural Science Foundation of China(22508239)

Innovative Talent Fund of Harbin City(L2025-ZDKJ-ZDGG-XCL001)

Yangzhou Science and Technology Bureau’s Industrial Forward-looking and Key Core Technology Project(YZ2025004)

Longyou County Science and Technology Bureau Major Science and Technology Research(JHXM2025188)

Xi'an Social Development Technology Innovation Demonstration Project (26SFJS00008)

RIGHTS & PERMISSIONS

Donghua University, Shanghai, China

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