Description:TECHNICAL FIELD
[0001] The embodiments of the present disclosure generally relate to the field of composite materials. More particularly, the present disclosure relates to a method for additive manufacturing of a fiber embedded polymer matrix composite.

BACKGROUND
[0002] The following description of the related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section is used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of the prior art.
[0003] Fused deposition modelling (FDM) is an additive layer manufacturing process that deposits thermoplastic material, layer-by-layer to produce complex geometries. On the other hand, additive layer manufacturing (ALM) fabricates objects from a three-dimensional (3D), computer-aided design (CAD) model by stacking material in the layer-by-layer arrangement. Further, additive manufacturing techniques can create various complex shapes and structures while properly managing materials, resulting in less waste.
[0004] Patent document WO2023156544A describes a composite material, with multiple compatible glass fibres in a thermoplastic polymer matrix. The invention further pertains to a method for obtaining a solid polymer composite material that includes biocompatible and resorbable glass fibres, which are embedded in a biocompatible and resorbable matrix polymer. However, the method in the referred patent does not involve the use of FDM based additive manufacturing.
[0005] Patent document CN108164942A describes a method for 3D printing and preparation of Polylactic Acid (PLA) composite materials. The method includes addition of short glass fibres in a base PLA during the filament manufacturing process where glass fibres are infused into the PLA filament prior to the printing process. However, the referred patent generates PLA composite materials with different functional groups, leading to distinct material properties.
[0006] Published document “Tensile properties of in situ 3D printed glass fiber-reinforced PLA” describes tensile behaviours of composites manufactured by FDM. Fiber doser is designed and fabricated to deposit the glass fiber powder during the 3D printing. However, the method in the referred document is based on fiber doser with a glass fiber embedding process, which is different from the method proposed in the present disclosure.
[0007] Published document “Woven natural fiber-reinforced PLA polymers 3D printed through a laminated object manufacturing process” describes the additive manufacturing method utilizing a laminated object manufacturing (LOM) technology with woven natural fiber-reinforced biopolymer. However, the method in the referred document does not involve the use of FDM based additive manufacturing.
[0008] Published document “Fused Deposition Modelling of Natural Fibre/Polylactic Acid Composite” describes production of filaments in varying weight percentages within the PLA polymer. However, natural fibre is used during the embedding process, which is different from the method proposed in the present disclosure.
[0009] Published document “Study on shock resistance of steel plate reinforced with polyurea–woven fiberglass mesh composite under shock wave” describes a finite element method simulation of polyurea–woven fiberglass mesh composite material. However, multi-layer glass fiber composite is sandwiched in steel plate along with foam, which is different from the method proposed in the present disclosure.
[0010] Therefore, there is a need for a process that produces high-performance composite materials.

OBJECTS OF THE PRESENT DISCLOSURE
[0011] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are listed herein below.
[0012] It is an object of the present disclosure to provide a method for additive manufacturing of a fiber embedded polymer matrix composite (FEPMC).
[0013] It is an object of the present disclosure to provide a method that includes generation of a polymer composite structure (also referred as the FEPMC) through fused deposition modeling (FDM) printing of multiple polymer structure layers.
[0014] It is an object of the present disclosure to provide a method where multiple fiber-mesh layers are intermittently disposed between the multiple polymer structure layers for a predetermined period for reinforcing the polymer composite structure.
[0015] It is an object of the present disclosure to provide a method where the multiple fiber-mesh layers, prior to intermittently disposing, are pre-treated with a nitrogen plasma process to align the fiber-mesh layers with principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure.
[0016] It is an object of the present disclosure to provide a method where the polymer composite structure, subsequent to intermittently disposing, is post-treated with a heat treatment process for providing structural integrity to the polymer composite structure.
[0017] It is an object of the present disclosure to provide a method where orientation of the multiple fiber-mesh layers is controlled to align with the principal stress directions, in order to optimize the strength-to-weight ratio of the generated polymer composite structure.

SUMMARY
[0018] This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.
[0019] In an aspect, the present disclosure relates to a method for additive manufacturing of a polymer composite structure. The method includes generating, the polymer composite structure through fused deposition modeling (FDM) printing of a plurality of polymer structure layers. The method includes reinforcing the polymer composite structure by intermittently disposing a plurality of fiber-mesh layers between the plurality of polymer structure layers for a predetermined period.
[0020] In an embodiment, the method may include pre-treating, prior to intermittently disposing, the plurality of fiber-mesh layers with a nitrogen plasma process to align the plurality of fiber-mesh layers with one or more principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure.
[0021] In an embodiment, the method may include post-treating, subsequent to intermittently disposing, the polymer composite structure with a heat treatment process for providing structural integrity to the of polymer composite structure.
[0022] In an embodiment, the FDM printing of the plurality of polymer structure layers may include generating a first polymer structure layer of the plurality of polymer structure layers using FDM printing for a predefined interval and generating a second polymer structure layer of the plurality of polymer structure layers using FDM printing on the first layer for the predefined interval.
[0023] In an embodiment, the method may include intermittently disposing, a first fiber mesh layer of the plurality of fiber mesh layers on the first polymer structure layer and intermittently disposing a second fiber layer of the plurality of fiber mesh layers on the second polymer structure layer.
[0024] In an embodiment, the polymer composite structure may include a synthetic woven fiber structure, and where each of the plurality of polymer structure layers may include a thermoplastic filament and each of the plurality of fiber-mesh layers may include a woven fiber mesh.
[0025] In an aspect, a method for additive manufacturing of a polymer composite structure include pre-treating, prior to intermittently disposing, a plurality of fiber-mesh layers with a nitrogen plasma process. The method includes generating, the polymer composite structure through fused deposition modeling (FDM) printing of a plurality of polymer structure layers. The method includes intermittently disposing, the plurality of pre-treated fiber-mesh layers between the plurality of polymer structure layers for a predetermined period. The method includes post-treating, subsequent to intermittently disposing, the generated polymer composite structure with a heat treatment process for providing structural integrity to the of polymer composite structure.
[0026] In an aspect, a polymer composite structure includes a plurality of polymer structure layers, where a plurality of fiber-mesh layers are intermittently disposed between the plurality of polymer structure layers for a predetermined period in order to reinforce the polymer composite structure.
[0027] In an embodiment, the plurality of fiber-mesh layers, prior to intermittently disposing may be pre-treated, with a nitrogen plasma process to align the plurality of fiber-mesh layers with one or more principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure.
[0028] In an embodiment, the polymer composite structure, subsequent to intermittently disposing, may be post-treated, with a heat treatment process for providing structural integrity to the of polymer composite structure.

BRIEF DESCRIPTION OF DRAWINGS
[0029] The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that disclosure of such drawings includes the disclosure of electrical components, electronic components, or circuitry commonly used to implement such components.
[0030] FIG. 1 illustrates an example schematic diagram (100) of the proposed method for a fiber embedded polymer matrix composite (FEPMC), in accordance with an embodiment of the present disclosure.
[0031] FIGs. 2A-2E illustrate example graphical representations (200A, 200B, 200C, 200D, 200E) of the proposed FEPMC of FIG. 1, in accordance with embodiments of the present disclosure.
[0032] FIG. 3 illustrates an example flow diagram (300) of a method used for the manufacturing of the FEPMC of FIG. 1, in accordance with embodiments of the present disclosure.
[0033] The foregoing shall be more apparent from the following more detailed description of the disclosure.

DETAILED DESCRIPTION
[0034] In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.
[0035] The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
[0036] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail to avoid obscuring the embodiments.
[0037] The word “exemplary” and/or “demonstrative” is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as “exemplary” and/or “demonstrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms “includes,” “has,” “contains,” and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising” as an open transition word without precluding any additional or other elements.
[0038] Reference throughout this specification to “one embodiment” or “an embodiment” or “an instance” or “one instance” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0039] All methods described herein can be performed in suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed.
[0040] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0041] The present disclosure describes a method for creating materials with a high strength-to-weight ratio using fiber embedded polymer matrix composite (FEPMC) (also referred as the polymer composite structure). The method uses an additive manufacturing process (also known as a three-dimensional (3D) printing technology) for manufacturing the FEPMC and meeting the requirements of various commercial applications. This method includes additive manufacturing techniques, notably Fused Deposition Modeling (FDM), to embed fiber layers within a polymer matrix, resulting in composite materials required for both strength and lightweight design. High-performance composite materials are generated by embedding fiber layers into a polymer matrix using FDM.
[0042] Various embodiments of the present disclosure will be explained in detail with reference to FIGs. 1-3.
[0043] FIG. 1 illustrates an example schematic diagram (100) of the proposed method for a fiber embedded polymer matrix composite (FEPMC), in accordance with an embodiment of the present disclosure.
[0044] In an embodiment, various commercial applications including, but not limited to aerospace industries (drone frames) require high strength-to-weight ratio materials for achieving the required mechanical properties for aviation. FDM particularly, uses small-scale thermoplastic materials to produce products for engineering. The adjustability to use different materials such as metallic, polymers, and ceramics have made the FDM technology applicable among various additive manufacturing (AM) processes. Different polymers including, but not limited to Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate (PET), Nylon, and Polypropylene Filament (PP) with required physical, thermal, and mechanical properties are used for FDM applications.
[0045] In an embodiment, the present disclosure describes a methodology for producing high-performance composite materials by embedding fiber layers into a polymer matrix using FDM printing. This process facilitates the creation of materials with complex geometries and optimized mechanical properties, achieving a superior strength-to-weight ratio essential for commercial applications. Further, the method addresses an impact resistance limitation of the material to broaden the material’s applicability in industries prioritizing durability. The method describes creation of an embedded/ sandwich structure with synthetic woven fibers and thermoplastics to maximize inherent properties of a high-strength polymer composite structure. The method allows for enhancing an impact resistance required for improved durability and structural integrity.
[0046] In an embodiment, a polymer composite structure (also referred as a polymer matrix) may be generated through fused deposition modeling (FDM) printing of a plurality of polymer structure layers. A plurality of fiber-mesh layers may be intermittently disposed between the plurality of polymer structure layers for a predetermined period for generating a multi-directional polymer composite structure. The multi-directional polymer composite structure may include a synthetic woven fiber structure. Further, each of the polymer structure layers may include a thermoplastic filament and each of the fiber-mesh layers may include a synthetic woven fiber mesh.
[0047] As illustrated in FIG.1, in an embodiment, a thermoplastic polymer structure layer (also referred as the polymer structure layer) with the required mechanical and thermal characteristics may be selected as the polymer structure layer. For example, a thermoplastic (102) may be selected in a filament form as the thermoplastic polymer structure layer. The filament may be dried to remove any moisture that could affect the 3D print quality and mechanical properties. A synthetic woven fiber (104) may be used for the construction of the plurality of fiber-mesh layers.
[0048] In an embodiment, the plurality of fiber-mesh layers may be pre-treated with a nitrogen plasma treatment (106), inside a plasma-based sputtering system for twenty minutes to enhance the surface properties of the plurality of fiber-mesh layers. The pre-treatment may align the plurality of fiber-mesh layers with one or more principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure (110).
[0049] In an embodiment, a digital model of the polymer structure layer (110) may be created using computer-aided design (CAD) software. The digital model may incorporate the intricate shapes and complex geometries required for the generation of the plurality of polymer structure layers. Further, the digital model may be processed using slicing software to generate the toolpaths for a FDM 3D printer. In an example embodiment, a polymer matrix base layer that is 0.8 mm thick (0.2 mm × 4 print layers) may be used as the first layer of the polymer structure layer. For the example 3D printing (108), the bed temperature may be maintained at about 60 degree celsius with a nozzle temperature of about 210 degree celsius. A print speed of about 55 millimetres (mm) per second and about 100 percent infill may be used. During the FDM printing process, the 3D printer may be programmed to pause at predefined intervals to allow for the placement of plasma-treated fiber mesh layers. The plasma-treated fiber-mesh layers may be disposed between the plurality of polymer structure layers for the predetermined period. Multiple plasma-treated fiber-mesh layers may be disposed at different stages of the 3D printing process to generate the multi-directional composite structure (110).
[0050] In an embodiment, the multi-directional polymer composite structure (110) may include generation, of a first polymer structure layer of the plurality of polymer structure layers using FDM printing for a predefined interval and generating a second polymer structure layer of the plurality of polymer structure layers using FDM printing on the first polymer structure layer for the predefined interval. Further, a first plasma-treated fiber mesh layer of the plurality of plasma-treated fiber mesh layers may be intermittently disposed on the first polymer structure layer and a second plasma-treated fiber mesh layer of the plurality of plasma-treated fiber mesh layers may be intermittently disposed on the second polymer structure layer. In this manner, the plurality of polymer structure layers and the plurality of plasma-treated fiber-mesh layers may be arranged to generate the polymer composite structure (110).
[0051] In an embodiment, the generated polymer composite structure (110) may be post-treated (112) with a heat treatment process for providing structural integrity to the of polymer composite structure (110). The polymer composite structure (110) after FDM printing may undergo the heat treatment process at 80 degree celsius for 35 minutes to increase the bonding between the plurality of polymer structure layers. Temperature and time for post-processing of the plurality of polymer structure layers may be selected based on the selected thermoplastic polymer.
[0052] In one or more embodiments, the method for additive manufacturing of the polymer composite structure (110) may include pre-treating, prior to intermittently disposing, the plurality of fiber-mesh layers with the nitrogen plasma process. The method may include generating, the polymer composite structure (110) through fused deposition modeling (FDM) printing of a plurality of polymer structure layers. The method may include intermittently disposing, the plurality of pre-treated fiber-mesh layers between the plurality of polymer structure layers for a predetermined period. The method may include post-treating, subsequent to intermittently disposing, the generated polymer composite structure (110) with a heat treatment process for providing structural integrity to the of polymer composite structure (110).
[0053] Therefore, in an embodiment, the generated polymer composite structure (110) may include the plurality of polymer structure layers, where the plurality of plasma treated fiber-mesh layers may be intermittently disposed between the plurality of polymer structure layers for a predetermined period in order to reinforce the polymer composite structure (110).
[0054] In an embodiment, the FEPMC composite structure (also referred as the post-treated polymer composite structure (110)) demonstrated about 20 percent improvement in tensile and flexural strength, a 19 percent improvement in strength-to-weight ratio, and about 30 percent improvement in energy absorption during impact when compared with conventional printed thermoplastic of the same dimension.
[0055] Further, in an embodiment, the post-treated polymer composite structure (110) may be characterized by a total thickness of about 2.4 mm. For example, the post-treated polymer composite structure (110) may include three layers of the polymer structure layers and two layers of the plasma treated fiber-mesh layers. Similarly, multiple plasma-treated fiber-mesh layers may be intermittently disposed between the plurality of polymer structure layers to form the multi-directional polymer composite structure (110).
[0056] Therefore, in an embodiment, the method for additive manufacturing of the multi-directional polymer composite structure (110) may produce sophisticated composite materials with a high strength-to-weight ratio specifically designed to meet the demanding requirements of various commercial applications. Superior mechanical performance and design flexibility may be guaranteed by the FDM technology’s inclusion of plasma-treated fiber-mesh layers within the multi-directional polymer composite structure (110). The composite materials developed using this methodology may be particularly suited for aeronautical applications, but also may be applicable to structural components of an aircraft, Unmanned Aerial Vehicle (UAV) parts, lightweight frames and support structures, and aerodynamic surfaces and fairings.
[0057] FIGs. 2A-2E illustrate example graphical representations (200A, 200B, 200C, 200D, 200E) of the proposed FEPMC of FIG. 1, in accordance with embodiments of the present disclosure.
[0058] In an embodiment, FIG. 2A illustrates a graphical representation of the tensile strength of the post-treated polymer composite structure (110) (also referred as the FEPMC). The FEPMC (110) exhibited a 20 percent increase in tensile strength when compared to a conventional printed thermoplastic of the same dimension.
[0059] In an embodiment, FIG. 2B illustrates a graphical representation of a strength to weight ratio of the FEPMC (110). The FEPMC (110) exhibited a 19 percent increase in the strength to weight ratio when compared to a conventional printed thermoplastic of the same dimension.
[0060] In an embodiment, FIG. 2C illustrates a graphical representation of a Drop Mass impact test performed on the FEPMC (110). The FEPMC (110) exhibited a 31 percent increase in the impact energy when compared to a conventional printed thermoplastic of the same dimension.
[0061] In an embodiment, FIG. 2D illustrates a graphical representation of the fiber-mesh layers disposed in the FEPMC (110). The FEPMC (110) exhibited a significant increase in elongation when compared to a conventional printed thermoplastic of the same dimension.
[0062] In an embodiment, FIG. 2E illustrates a graphical representation of the flexural strength of the FEPMC (110). The FEPMC (110) exhibited a 20 percent increase in the flexural strength when compared to a conventional printed thermoplastic of the same dimension.
[0063] FIG. 3 illustrates an example flow diagram (300) of a method used for the manufacturing of the FEPMC of FIG. 1, in accordance with embodiments of the present disclosure.
[0064] As illustrated in FIG. 3, the method for manufacturing the FEPMC (110) may include the following steps.
[0065] At step 302: The method may include generating, a polymer composite structure (110) through FDM printing of a plurality of polymer structure layers.
[0066] At step 304: The method may include reinforcing the polymer composite structure (110) by intermittently disposing a plurality of fiber-mesh layers between the plurality of polymer structure layers for a predetermined period.
ADVANTAGES OF THE INVENTION
[0067] The present disclosure provides a method for generation of a fiber embedded polymer matrix composite (FEPMC) (also referred as the polymer composite structure) through fused deposition modeling (FDM) of multiple polymer structure layers.
[0068] The present disclosure provides a method where the polymer composite structure is generated through fused deposition modeling (FDM) printing of multiple of polymer structure layers. The polymer composite structure is reinforced by intermittently disposing multiple fiber-mesh layers between the polymer structure layers for a predetermined period.
[0069] The present disclosure provides a method where the multiple fiber-mesh layers prior to intermittently disposing, are pre-treated with a nitrogen plasma process to align the fiber-mesh layers with principal stress directions, required to optimize a strength-to-weight ratio of the polymer composite structure.
[0070] The present disclosure provides a method where the polymer composite structure subsequent to intermittently disposing, is post-treated with a heat treatment process for providing structural integrity to the of polymer composite structure.
[0071] The present disclosure provides a method where orientation of the multiple fiber-mesh layers is controlled to align with the principal stress directions in order to optimize the strength-to-weight ratio of the generated polymer composite structure.
, Claims:1. A method (300) for additive manufacturing of a polymer composite structure (110), the method (300) comprising:
generating (302), the polymer composite structure (110) through fused deposition modeling (FDM) printing of a plurality of polymer structure layers; and
reinforcing the polymer composite structure (110) by intermittently disposing a plurality of fiber-mesh layers between the plurality of polymer structure layers for a predetermined period.

2. The method (300) as claimed in claim 1, comprising pre-treating, prior to intermittently disposing, the plurality of fiber-mesh layers with a nitrogen plasma process to align the plurality of fiber-mesh layers with one or more principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure (110).

3. The method (300) as claimed in claim 1, comprising post-treating, subsequent to intermittently disposing, the polymer composite structure (110) with a heat treatment process for providing structural integrity to the of polymer composite structure (110).

4. The method (300) as claimed in claim 1, wherein the FDM printing of the plurality of polymer structure layers comprises:
generating a first polymer structure layer of the plurality of polymer structure layers using FDM printing for a predefined interval and generating a second polymer structure layer of the plurality of polymer structure layers using FDM printing on the first polymer structure layer for the predefined interval.

5. The method (300) as claimed in claim 5, comprising intermittently disposing, a first fiber mesh layer of the plurality of fiber mesh layers on the first polymer structure layer and intermittently disposing a second fiber layer of the plurality of fiber mesh layers on the second polymer structure layer.

6. The method (300) as claimed in claim 1, wherein the polymer composite structure (110) comprises a synthetic woven fiber structure, and wherein each of the plurality of polymer structure layers comprises a thermoplastic filament and each of the plurality of fiber-mesh layers comprises a woven fiber mesh.

7. A method (400) for additive manufacturing of a polymer composite structure (110), the method (400) comprising:
pre-treating, prior to intermittently disposing, a plurality of fiber-mesh layers with a nitrogen plasma process;
generating, the polymer composite structure (110) through fused deposition modeling (FDM) printing of a plurality of polymer structure layers;
intermittently disposing, the plurality of pre-treated fiber-mesh layers between the plurality of polymer structure layers for a predetermined period;
post-treating, subsequent to intermittently disposing, the generated polymer composite structure (110) with a heat treatment process for providing structural integrity to the of polymer composite structure (110).

8. A polymer composite structure (110) comprising: a plurality of polymer structure layers, wherein a plurality of fiber-mesh layers are intermittently disposed between the plurality of polymer structure layers for a predetermined period in order to reinforce the polymer composite structure (110).
9. The polymer composite structure (110) as claimed in claim 8, wherein the plurality of fiber-mesh layers, prior to intermittently disposing are pre-treated, with a nitrogen plasma process to align the plurality of fiber-mesh layers with one or more principal stress directions required to optimize a strength-to-weight ratio of the polymer composite structure (110).

10. The polymer composite structure (110) as claimed in claim 8, wherein the polymer composite structure (110), subsequent to intermittently disposing, is post-treated, with a heat treatment process for providing structural integrity to the polymer composite structure (110).