Shaping the future of hybrid composites: Emerging innovations in hybrid nickel-titanium composite manufacturing and performance

The growing demand for lightweight, high-performance structures with integrated intelligence has accelerated the development of advanced smart materials. Among them, nickel–titanium (NiTi) shape memory alloys (SMAs) and their composites are particularly attractive due to their reversible phase transformation capability, enabling adaptive, self-responsive, and multifunctional behavior. When integrated into composite systems, NiTi-SMAs significantly enhance actuation performance, vibration suppression, damping capacity, and self-healing functionality, making them promising candidates for next-generation aerospace structures. This review provides a comprehensive assessment of recent advances in the manufacturing and integration of NiTi-SMAs within composite architectures, with emphasis on aerospace applications such as actuators, deployable space components, and morphing structures. Although these systems have demonstrated strong technical feasibility and economic potential, challenges related to cyclic stability, scalable processing, and mass-efficient structural design continue to limit broader implementation. Advanced manufacturing approaches, particularly powder bed fusion and direct energy deposition, are critically examined in this context. Finally, emerging research directions are elaborated with a focus on machine learning (ML) frameworks capable of modeling complex process–structure–property relationships in NiTi-SMAs. By linking composition and processing parameters to structural and functional performance, ML approaches offer a pathway for accelerated optimization and the development of next-generation smart aerospace systems.