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DESIGN, SIMULATION AND TESTING TECHNOLOGIES FOR NEXT-GEN COMPOSITE STRUCTURES

The highly engineered nature of composite structures and the ability to orient fiber reinforcements where they are needed to meet specific mechanical forces has been, for decades, the selling point of these advanced materials. This attribute, combined with advances in manufacturing capability, has accelerated penetration of composites into complex structures in aerospace, defense, energy, automotive, wind, marine, and many other end markets. Composite materials have evolved to become the de facto standard for applications that demand high strength and light weight.

Complicating matters is the multi-variant challenge posed by the complex recipe of fiber reinforcements, resin matrices, tooling and manufacturing processes that are deployed in composites manufacturing, which makes design, modeling and simulation equally complex. The composites community thus faces a highly dynamic, fast-evolving materials and process landscape that has compelled design engineers and CAD developers to be equally flexible and fast-evolving. They are producing products and systems that have enabled faster, more accurate, more robust designs that increasingly reflect the as-manufactured product.

CompositesWorld’s Tech Days: Design, Simulation and Testing Technologies for Next-Gen Composite Structures is designed to provide a multi-perspective view of the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection. This one-day online event will feature presentations from design and materials experts representing a range of composites industry stakeholders including academia, CAD and CAE software suppliers, laboratories, and fabricators. They will provide insight and perspective on design for aerostructures, materials trade studies, virtual testing, design for additive manufacturing, modeling and simulation strategies, product development acceleration, and much more. CompositesWorld hopes this Tech Days event will help you develop an understanding of how the composites design landscape is evolving and how new and emerging tools might be used to help you optimize your own designs and structures.

Join us. 

- Jeff Sloan, Editor-In-Chief, CompositesWorld

Review the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

During nine 30-minute Tech Day webinar sessions, materials and design engineering experts will assess the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

Reserve Your Spot

Presentations

Application of digital engineering methods to support the development and certification of composite unmanned air vehicles

In this presentation, Gerardo Olivares from the National Institute for Aviation Research (NIAR) will describe the five elements required to apply Digital Engineering Principles to develop and certify composite aircraft structures. An application of this approach will be presented to show how NIAR envisions the use of DE to support the development and certification of future composite UAVs.

Eduardo Barocio

Validated simulations for additive manufacturing

The multiple phenomena developed during the additive manufacturing (AM) printing process can lead to residual stresses, warpage, or delamination that can result into expensive print failures. Hence, validated simulations are paramount to enhance the confidence in AM technologies and to accelerate product development. Simulation predictions for Large Scale Additive Manufacturing carried out with Additive3D, a physics-based simulation workflow for AM, will be demonstrated in this presentation by Eduardo Barocio from Purdue University/Composites Manufacturing and Simulation Center.

De-risking the hybrid overmolding design process

In this presentation, Pete Levesque will review how Victrex is leveraging existing software packages for designing and de-risking thermoplastic composite hybrid overmolded designs.

Material trades strategies for composite structures

This presentation by Craig Collier from Collier Aerospace is a live demonstration of optimizing the acreage surfaces and the fastened and bonded joints of a commercial transport stiffened panel wing, and that of UAM sandwich panel wing.

Computed tomography: From R&D to inline quality assurance for composites

Computed tomography (CT) is a great tool for material characterization and quality assurance throughout the entire product life cycle of composite structures, from research and development to production and complaints investigation. For example, in material and component development, fiber orientations can be calculated based on CT scans to validate flow or draping simulations. The same data can also be used for finite element (FE) simulations in structural mechanics to improve material efficiency, design cheaper and lighter components with the same or higher reliability, or investigate the integrity of entire components at end-of-line inspections.

Multiscale material modeling, manufacturing simulation, and structural simulation to advance composite design and analysis

Jeff Wollschlager will highlight the integration and democratization developments occurring within the Altair Composites Solutions team, a demonstration of the Injection Molding and Composite Pressure Vessel (CPV) workflows within the Altair HyperWorks Product Suite will be shown and discussed.

New Space: Use of digital tools to enable the digital factory and to create digital twins

Founded in 2017, Firefly has rapidly innovated and developed products for the marketplace that include the largest liquid-propellant all-composite orbital launch vehicle Alpha, Blue Ghost Lunar Lander, and in-space transportation solutions. Firefly uses many commercial off-the-shelf (COTS) materials in non-standard ways, to populate products digitally, rapidly iterate, both through digital optimization and a “make it, break it, make it, fly it” approach. John Courter, Director of the Aerospace Structurers Group at Firefly will share some of these experiences and expand on what Firefly believes to be a mutually beneficial supplier-consumer relationship.

Using material digital twins and machine learning to more accurately predict as-manufactured performance

Virtual material testing reduces the number of experimental tests to be performed and is used to efficiently screen different materials and microstructures for an optimized performance. In addition, machine learning techniques can be leveraged to further accelerate the material data generation and selection. The following example will be used to highlight the benefit of material digital twins and ICME based simulations: automatic fiber placement induces fiber orientations and the presence of tow gaps or defects during the manufacturing process of parts.

Design automation for composite airframes

This presentation will show how Spirit AeroSystems fully automated of the design of composite frame within CATIA. It will show how a complex part can be broken down into discrete segments to facilitate automation of design across a family of parts.