Alexander Safonov is an Associate Professor in the Composite Materials and Structures Laboratory at Skoltech Center for Materials Technologies (CMT). Key areas include polymer composite technology, mechanics of composite materials, numerical analysis of technological processes, topology optimization of structures, constitutive modeling of materials, FEM analysis of products, bionic design, and geomorphology.

Alexander Safonov obtained his MSc at Lomonosov Moscow State University (MSU), working on the thermo-viscoelastic constitutive equations for composite materials. In 2002 after his MSc he worked in the industry for the largest Russian company in the field of advanced technologies and construction with composite materials ApATeCh ltd. In 2006 he obtained his PhD in Research Institute for Machine Science named after A.A.Blagonravov of the Russian Academy of Sciences (IMASH RAN), entitled “Mathematical simulation of mechanics of pultrusion process of GFRP parts”, which concerns the numerical analysis of various processes in the composite profile during pultrusion. In 2011 he joined Central Aerohydrodynamic Institute (TSAGI), he supervised the execution of industrial research contracts for the Ministry of Industry and Trade. In 2014 he joined the Skoltech as leading research scientist at CMT. He did research and industrial projects with PJSC UAC, TSAGI and University Partners. The aim of the projects was development of the mathematical modeling methods for the technological process of manufacturing large-size composite aviation structures. In 2019 he was appointed as an Associate Professor in the Skoltech.

Prof. Safonov’s research work currently focuses on developing the pultrusion process to fabricate structural profiles of fiber reinforced thermoplastic materials. Thermoplastic composites offer several advantages such as higher crack resistance and damage tolerance due to the higher ultimate strain of matrix; shorter production cycle due to the absence of chemical reactions during fabrication; excellent environmental resistance; and thermoforming capabilities as thermoplastic matrix melts under high temperatures without chemical destruction. The main goal is to develop the process to fabricate of structural profiles and structures of fiber reinforced thermoplastic materials, capable to compete with and outperform those of traditional thermoset materials.

Publications

• Lomov, S. V.; Karamov, R.; Burukhin, A.; Emon, M.; Minchenkov, K.; Gusev, S.; Li, C.; Xian, G.; Safonov, A.A. Manufacturing-caused distortion of fibrous microstructure in bidirectional pultruded E-glass/polypropylene thermoplastic composites. Results in Engineering 2026, 29, 108672, doi:10.1016/j.rineng.2025.108672
• Pal, S.; Beloozerova, J.; Yavorsky, Y.; Gusev, S.; Safonov, A. Durability study of thermoplastic pultruded composites based on polyamide. Results in Engineering 2025, 28, 108343, doi:10.1016/j.rineng.2025.108343
• Emon, M.; Minchenkov, K.; Gusev, S.; Li, C.; Xian, G.; Safonov, A. Pultrusion of glass fiber reinforced polypropylene bidirectional composites and their mechanical performance. Scientific Reports 2025, 15, 39904, doi:10.1038/s41598-025-23744-y
• Makeera, S.; Yavorsky, Y.; Gusev, S.; Voloskov, B.; Konev, S.; Karamov, R.; Fomina, E.; Li, C.; Xian, G.; Safonov, A. Fatigue performance and failure mechanisms of pultruded GF/PP rivets in single lap composite joints. Materials & Design 2025, 260, 115202, doi:10.1016/j.matdes.2025.115202
• Özkılıç, Y; Madenci, E; Safonov, A; Gemi, L; Yazman, Ş. Comprehensive Evaluation of Tensile Properties, Damage Mechanisms, and Predictive Modeling of Pultruded GFRP After Elevated Temperatures. Composites Part B: Engineering 2025, 112657, doi:10.1016/j.compositesb.2025.112657
• Moskaleva, A.; Safonov, A.; Hernandez-Montes, E. The impact of force:length ratio patterns on buckling resistance of shell structures. Engineering Structures 2025, 332, 120037, doi:10.1016/j.engstruct.2025.120037
• Minchenkov, K.; Gusev, S.; Sergeichev, I.; Safonov, A. Improving the thermal performance of PVC windows with pultruded thermoplastic reinforcement. Scientific Reports 2025, 15, 1996, doi:10.1038/s41598-025-86019-6
• Moskaleva, A.; Gusev, S.; Konev, S.; Hernandez-Montes, E.; Safonov, A. Stiffening patterns for freeform composite shell structures. Thin-Walled Structures 2024, 201, 112037, doi:10.1016/j.tws.2024.112037
• Elkin, A.; Konev, S.; Safonov, A.; Gusev, S.; Sergeichev, I. Compressive residual strength of the pultruded glass-fiber composite after tension-compression fatigue. Composites Part C: Open Access 2024, 14, 100456, doi:10.1016/j.jcomc.2024.100456
• Kravtsova, V.; Minchenkov, K.; Gusev, S.; Evlashin, S.; Bondareva, J.; Alajarmeh, O.; Safonov, A. Recyclability of unidirectional reinforced pultruded thermoplastic profiles into composite laminates. Composites Communications 2024, 46, 101843, doi:10.1016/j.coco.2024.101843
• Minchenkov, K.; Gusev, S.; Rogozheva, A.; Tronin, A.; Diatlova, M.; Safonov, A. Pultrusion of thermoplastic composites with mechanical properties comparable to industrial thermoset profiles. Composites Communications 2023, 44, 101766, doi:10.1016/j.coco.2023.101766
• Minchenkov, K.; Gusev, S.; Sulimov, A.; Alajarmeh, O.; Sergeichev, I.; Safonov, A. Experimental and numerical analyses of the thermoplastic pultrusion of large structural profiles. Materials & Design 2023, 232, 112149, doi:10.1016/j.matdes.2023.112149
• Romanovskaia, N.; Minchenkov, K.; Gusev, S.; Klimova-Korsmik, O.; Safonov, A. Effects of Additives on the Mechanical and Fire Resistance Properties of Pultruded Composites. Polymers 2023, 15, 3581. doi:10.3390/polym15173581
• Safonov, A.; Minchenkov, K. Mathematical Simulation of Honeycomb Weathering via Moisture Transport and Salt Deposition. Geosciences 2023, 13, 161. doi:10.3390/geosciences13060161
• Alajarmeh, O.; Manalo, A.; Ferdous, W.; Almasabha, G.; Tarawneh, A.; Awwad, K.E.; Safonov, A.; Zeng, X.; Schubel, P. Fatigue behavior of unidirectional fiber‐reinforced pultruded composites with high volume fiber fraction. Fatigue & Fracture of Engineering Materials & Structures 2023, 46, 6, doi:10.1111/ffe.13979
• Bondareva, J.V.; Chernodoubov, D.A.; Dubinin, O.N.; Tikhonov, A.A.; Simonov, A.P.; Suetin, N.V.; Tarkhov, M.A.; Popov, Z.I.; Kvashnin, D.G.; Evlashin, S.A.; Safonov, A.A. Thermal and Electrical Properties of Additively Manufactured Polymer–Boron Nitride Composite. Polymers 2023, 15, 1214, doi:10.3390/polym15051214
• Moskaleva, A.; Gusev, S.; Konev, S.; Sergeichev, I.; Safonov, A.; Hernandez-Montes, E. Composite freeform shell structures: Design, construction and testing. Composite Structures 2023, 306, 116603, doi:10.1016/j.compstruct.2022.116603
• Vedernikov, A.; Gemi, L.; Madenci, E.; Onuralp Özkılıç, Y.; Yazman, Ş.; Gusev, S.; Sulimov, A.; Bondareva, J.; Evlashin, S.; Konev, S.; Akhatov, I.; Safonov, A. Effects of high pulling speeds on mechanical properties and morphology of pultruded GFRP composite flat laminates. Composite Structures 2022, 301, 116216, doi:10.1016/j.compstruct.2022.116216
• Minchenkov, K.; Vedernikov, A.; Kuzminova, Y.; Gusev, S.; Sulimov, A.; Gulyaev, A.; Kreslavskaya, A.; Prosyanoy, I.; Xian, G.; Akhatov, I.; Safonov, A. Effects of the quality of pre-consolidated materials on the mechanical properties and morphology of thermoplastic pultruded flat laminates. Composites Communications 2022, 35, 101281, doi:10.1016/j.coco.2022.101281
• Gemi, L.; Madenci, E.; Özkılıç, Y.O.; Yazman, Ş.; Safonov, A. Effect of Fiber Wrapping on Bending Behavior of Reinforced Concrete Filled Pultruded GFRP Composite Hybrid Beams. Polymers 2022, 14, 3740. doi:10.3390/polym14183740
• Aksoylu C, Özkılıç YO, Madenci E, Safonov A. Compressive Behavior of Pultruded GFRP Boxes with Concentric Openings Strengthened by Different Composite Wrappings. Polymers 2022; 14(19):4095. doi:10.3390/polym14194095
• Madenci, E.; Özkılıç, Y.O.; Aksoylu, C.; Safonov, A. The Effects of Eccentric Web Openings on the Compressive Performance of Pultruded GFRP Boxes Wrapped with GFRP and CFRP Sheets. Polymers 2022, 14, 4567. doi:10.3390/polym14214567
• Zhou, P.; Li, C.; Bai, Y.; Dong, S.; Xian, G.; Vedernikov, A.; Akhatov, I.; Safonov, A.; Yue, Q. Durability study on the interlaminar shear behavior of glass-fibre reinforced polypropylene (GFRPP) bars for marine applications. Construction and Building Materials 2022, 349, 128694, doi:10.1016/j.conbuildmat.2022.128694
• Novikov, I. V.; Krasnikov, D. V.; Vorobei, A.M.; Zuev, Y.I.; Butt, H.A.; Fedorov, F.S.; Gusev, S.A.; Safonov, A.A.; Shulga, E. V.; Konev, S.D.; Sergeichev, I.V; Zhukov, S.S.; Kallio, T.; Gorshunov, B.P.; Parenago, O.O.; Nasibulin, A.G. Multifunctional Elastic Nanocomposites with Extremely Low Concentrations of Single-Walled Carbon Nanotubes. ACS Applied Materials & Interfaces 2022, 14, 18866–18876, doi:10.1021/acsami.2c01086
• Vedernikov, A.; Minchenkov, K.; Gusev, S.; Sulimov, A.; Zhou, P.; Li, C.; Xian, G.; Akhatov, I.; Safonov, A. Effects of the Pre-Consolidated Materials Manufacturing Method on the Mechanical Properties of Pultruded Thermoplastic Composites. Polymers 2022, 14, 2246. doi:10.3390/polym14112246
• Korotkov, R.; Vedernikov, A.; Gusev, S.; Alajarmeh, O.; Akhatov, I.; Safonov, A. Shape memory behavior of unidirectional pultruded laminate. Composites Part A: Applied Science and Manufacturing 2021, 150, 106609, doi:10.1016/j.compositesa.2021.106609.
• Moskaleva, A.; Safonov, A.; Hernández-Montes, E. Fiber-Reinforced Polymers in Freeform Structures: A Review. Buildings 2021, 11, 481, https://doi.org/10.3390/buildings1110048.
• Alajarmeh, O.; Zeng, X.; Aravinthan, T.; Shelley, T.; Alhawamdeh, M.; Mohammed, A.; Nicol, L.; Vedernikov, A.; Safonov, A.; Schubel, P. Compressive behaviour of hollow box pultruded FRP columns with continuous-wound fibres. Thin-Walled Structures 2021, 168, 108300, doi:10.1016/j.tws.2021.108300.
• Vedernikov, A.; Safonov, A.; Tucci, F.; Carlone, P.; Akhatov, I. Modeling Spring-In of L-Shaped Structural Profiles Pultruded at Different Pulling Speeds. Polymers 2021, 13, 2748, doi:10.3390/polym13162748.
• Popov, D.; Kuzminova, Y.; Maltsev, E.; Evlashin, S.; Safonov, A.; Akhatov, I.; Pasko, A. CAD/CAM System for Additive Manufacturing with a Robust and Efficient Topology Optimization Algorithm Based on the Function Representation. Applied Sciences 2021, 11, 7409, doi:10.3390/app11167409.
• Vedernikov, A.; Nasonov, Y.; Korotkov, R.; Gusev, S.; Akhatov, I.; Safonov, A. Effects of additives on the cure kinetics of vinyl ester pultrusion resins. Journal of Composite Materials 2021, doi:10.1177/00219983211001528.
• Minchenkov, K.; Vedernikov, A.; Safonov, A.; Akhatov, I. Thermoplastic pultrusion: A review. Polymers 2021, 13(2), 180, doi:10.3390/polym13020180.
• Vedernikov, A.; Tucci, F.; Carlone, P.; Gusev, S.; Konev, S.; Firsov, D.; Akhatov, I.; Safonov, A. Effects of pulling speed on structural performance of L-shaped pultruded profiles. Composite Structures 2021, 255, 112967, doi:10.1016/j.compstruct.2020.112967.
• Safonov, A.; Maltsev, E.; Chugunov, S.; Tikhonov, A.; Konev, S.; Evlashin, S.; Popov, D.; Pasko, A.; Akhatov I. Design and Fabrication of Complex-Shaped Ceramic Bone Implants via 3D Printing Based on Laser Stereolithography. Applied Sciences 2020, 10(20), 7138, doi:10.3390/app10207138.
• Vedernikov, A.; Safonov, A.; Tucci, F.; Carlone, P.; Akhatov, I. Pultruded materials and structures: A review. Journal of Composite Materials 2020, 54, 4081–4117, doi:10.1177/0021998320922894.
• Safonov, A.; Filippi, M.; Mašín, D.; Bruthans, J. Numerical modeling of the evolution of arcades and rock pillars. Geomorphology 2020, 365, 107260, doi:10.1016/j.geomorph.2020.107260.
• Safonov, A.; Gusev, M.; Saratov, A.; Konstantinov, A.; Sergeichev, I.; Konev, S.; Gusev, S.; Akhatov, I. Modeling of cracking during pultrusion of large-size profiles. Composite Structures 2020, 235, 111801, doi:10.1016/j.compstruct.2019.111801.
• Nasonov Y.; Safonov A.; Gusev S.; Akhatov I. Effect of additives on cure kinetics of pultrusion resins. Procedia Manufacturing 2020, 47, 920–4, doi:10.1016/j.promfg.2020.04.283.
• Vedernikov A.; Tucci F.; Safonov A.; Carlone P.; Gusev S.; Akhatov I. Investigation on the Shape Distortions of Pultruded Profiles at Different Pulling Speed. Procedia Manufacturing 2020, 47, 1–5, doi:10.1016/j.promfg.2020.04.107.
• Safonov, A.; Chugunov, S.; Tikhonov, A.; Gusev, M.; Akhatov, I. Numerical simulation of sintering for 3D-printed ceramics via SOVS model. Ceramics International 2019, 45, 19027–19035, doi:10.1016/j.ceramint.2019.06.144.
• Safonov, A.A. 3D topology optimization of continuous fiber-reinforced structures via natural evolution method. Composite Structures 2019, 215, 289–297, doi:10.1016/j.compstruct.2019.02.063.
• Salimon, A.I.; Statnik, E.S.; Zadorozhnyy, M.Y.; Senatov, F.S.; Zherebtsov, D.D.; Safonov, A.A.; Korsunsky, A.M. Porous Open-Сell UHMWPE: Experimental Study of Structure and Mechanical Properties. Materials 2019, 12, 2195, doi:10.3390/ma12132195.
• Safonov, A.A.; Carlone, P.; Akhatov, I. Mathematical simulation of pultrusion processes: A review. Composite Structures 2018, 184, 153–177, doi:10.1016/j.compstruct.2017.09.093.
• Safonov, A.; Adamatzky, A. Computing via material topology optimisation. Applied Mathematics and Computation 2018, 318, 109–120, doi:10.1016/j.amc.2017.08.030.
• Safonov, A.A. Computing via natural erosion of sandstone. International Journal of Parallel, Emergent and Distributed Systems 2018, 33, 742–751, doi:10.1080/17445760.2018.1455836.
• Ostanin, I.; Safonov, A.; Oseledets, I. Natural Erosion of Sandstone as Shape Optimisation. Scientific Reports 2017, 7, 17301, doi:10.1038/s41598-017-17777-1.
• Shakhova, I.; Mironov, E.; Azarmi, F.; Safonov, A. Thermo-electrical properties of the alumina coatings deposited by different thermal spraying technologies. Ceramics International 2017, 43, 15392–15401, doi:10.1016/j.ceramint.2017.08.080.
• Dubinskii, S. V.; Safonov, A.A. Composite-friendly approach to certification of advanced materials and fabrication methods used in aviation industry. Journal of Machinery Manufacture and Reliability 2017, 46, 501–506, doi:10.3103/S1052618817050041.
• Tinkov, D.V.; Safonov, A.A. Design optimization of truss bridge structures of composite materials. Journal of Machinery Manufacture and Reliability 2017, 46, 46–52, doi:10.3103/S1052618817010149.
• Fedulov, B.N.; Safonov, A.A.; Kantor, M.M.; Lomov, S. V. Modelling of thermoplastic polymer failure in fiber reinforced composites. Composite Structures 2017, 163, 293–301, doi:10.1016/j.compstruct.2016.11.091.
• Safonov, A.; Jones, J. Physarum computing and topology optimisation. International Journal of Parallel, Emergent and Distributed Systems 2017, 32, 448–465, doi:10.1080/17445760.2016.1221073.
• Fedulov, B.; Fedorenko, A.; Safonov, A.; Lomakin, E. Nonlinear shear behavior and failure of composite materials under plane stress conditions. Acta Mechanica 2017, 1–8, doi:10.1007/s00707-017-1817-4.
• Fedulov, B.N.; Safonov, A.A.; Sergeichev, I. V.; Ushakov, A.E.; Klenin, Y.G.; Makarenko, I. V. Strength Analysis and Process Simulation of Subway Contact Rail Support Bracket of Composite Materials. Applied Composite Materials 2016, 23, 999–1013, doi:10.1007/s10443-016-9495-2.
• Fedulov, B.; Antonov, F.; Safonov, A.; Ushakov, A.; Lomov, S. Influence of fibre misalignment and voids on composite laminate strength. Journal of Composite Materials 2015, 49, 2887–2896, doi:10.1177/0021998314557533.
• Ushakov, A.E.; Safonov, A.A.; Sergeichev, I. V.; Fedulov, B.N.; Kornienko, E.I.; Timofeev, M.A.; Izotov, A. V.; Klenin, Y.G.; Rozin, N. V. Design and optimization of a vacuum infusion technological process for hopper car fabrication using polymeric composite materials. Journal of Machinery Manufacture and Reliability 2015, 44, 276–282, doi:10.3103/S105261881503022X.
• Sergeichev, I.V.; Antonov, F.K.; Safonov, A.A.; Ushakov, A.E. Estimation of residual strength of components of composite constructions after low-speed impact. Journal of Machinery Manufacture and Reliability 2013, 42, doi:10.3103/S1052618813010111.
• Shcheglov, B.A.; Safonov, A.A. Methods for determining the permeability of an orthotropic medium. Journal of Machinery Manufacture and Reliability 2012, 41, 229–236, doi:10.3103/S1052618812030090.
• Safonov, A.A.; Shcheglov, B.A. Mathematical modeling of polymerization in the manufacturing of polymeric composite materials. Journal of Machinery Manufacture and Reliability 2011, 40, doi:10.3103/S105261881106015X.
• Safonov, A. A. Mathematical description of the technological process of injection pultrusion. Journal of Machinery Manufacture and Reliability 2011, 40, 68–73, doi:10.3103/S1052618811010171.
• Sorina, T.G.; Safonov, A.A.; Khairetdinov, A.K. Pecularities of using carbon glass-reinforced plastic in pultrusion composite profiles for bridge engineering. Journal of Machinery Manufacture and Reliability 2010, 39, doi:10.3103/S1052618810010073.
• Safonov, A.A. Mathematical modeling for impregnation of reinforcing filler of fiberglasses during vacuum infusion. Journal of Machinery Manufacture and Reliability 2010, 39, 568–574, doi:10.3103/S1052618810060105.
• Safonov, A.A.; Suvorova, Y.V. Optimization of the pultrusion process for a rod with a large diameter. Journal of Machinery Manufacture and Reliability 2009, 38, doi:10.3103/S1052618809060090.