Glass fibers for advanced composites: Manufacturing, surface engineering, performance-driven selection and future direction

Glass fibers are among the most widely used reinforcement materials in polymer composite systems because of their favorable strength-to-weight ratio, thermal stability, electrical insulation, corrosion resistance, and cost-effective large-scale production. This review aims to provide an integrated understanding of glass fibers for advanced composites by linking glass chemistry, continuous fiber manufacturing, surface engineering, composite performance, application-driven material selection, and future research directions. The review critically examines the historical development, industrial manufacturing routes, major glass fiber types, sizing and chemistry, nanoparticle-based coatings, fiber-matrix interphase behavior, processing–microstructure–property relationships, and representative applications in the aerospace, automotive, construction, marine, electronics, and renewable energy sectors. The reviewed literature shows that the final performance of glass fiber-reinforced composites is governed not only by intrinsic fiber properties but also by melt-processing stability, fiber diameter, flaw distribution, sizing durability, matrix compatibility, processing route, and long-term environmental exposure. Recent developments in interphase engineering, nanoparticle coatings, recycling, remelting, re-sizing, and service-life prediction are also discussed as emerging routes to improve durability and sustainability. This review highlights that future progress in glass fiber composites will depend on stronger integration between composition design, scalable manufacturing, surface modification, performance-based material selection, and predictive lifetime modelling. These insights are expected to support the development of more reliable, durable, recyclable, and application-specific glass fiber-reinforced composites for high-performance engineering applications.