Adaptive Structures and Additive Technologies for Defensive Missiles

Nur Fatin Ashiqin Ahmad Ridzwan, Wan Luqman Hakim Wan A Hamid

The rapid evolution of modern missile threats, particularly in the hypersonic regime, has driven the need for highly integrated defensive missile systems capable of operating autonomously and reliably under extreme aerodynamic, thermal, and structural conditions. This review presents a comprehensive examination of adaptive and additive structures technology for defensive missiles, emphasizing the interdependent roles of aerodynamics, structural optimization, guidance and control, materials, and additive manufacturing. Missile classifications based on trajectory, function, and geometry are first reviewed to establish the operational context, followed by an in-depth discussion of aerodynamic and structural optimization strategies, including noncircular forebody designs, folding arc-wing configurations, aeroelastic effects, and nose cone trade-offs in hypersonic flow regimes. The review further analyzes advanced adaptive guidance and control architectures, highlighting the limitations of conventional reactive laws and the growing importance of nonlinear adaptive, vision-based, and AI-assisted guidance systems for intercepting highly maneuverable targets. Material considerations for hypersonic environments are discussed, with particular focus on carbon–carbon composites, ultra-high temperature ceramics, and honeycomb sandwich structures that balance thermal resistance, structural integrity, and weight efficiency. Finally, the strategic role of additive manufacturing is evaluated, demonstrating its impact on rapid prototyping, modular hypersonic testing infrastructure, and the fabrication of mission-critical components with reduced cost and lead time. Overall, this review underscores that future defensive missile development requires a tightly coupled, multidisciplinary systems approach, where aerodynamic efficiency, structural resilience, intelligent guidance, and advanced manufacturing technologies are co-optimized to meet the demands of next-generation hypersonic defense systems.