Design and numerical modelling strategy to form Tailored Fibre Placement preforms: Application to the tetrahedral part with orthotropic final configuration

Tailored Fibre Placement (TFP) allows manufacturing net shape preforms with continuously varying orientations and thickness. This additive technology, combined forming, enables the design of fibre reinforced composite parts optimized orientations. A new modelling strategy to simulate forming thin dry TFP preform without backing material is proposed. The finite element model based on an embedded formulation, which assumes stitching yarn act as a bond between tows adjacent layers. are modelled 2-node beam elements having independent generalized stress stiffnesses. tetrahedral orthotropic final configuration addressed both experimentally numerically validate proposed approach. has direct industrial application since it corresponds corner brackets. study also demonstrates ability improve mechanical properties engineered part using hybrid TFP-forming process.