Avoiding “build-to-print” in polymer composites: design and manufacturing decision support at the conceptual stages

Composite component manufacturers are often faced with having to quote and produce products “Built-to-Print”. Often, polymer composite component blueprints/drawings/CAD files are designed under insufficient paradigms and mirror features common in metal components. Composites, which are composed of a plastic resin matrix and reinforcing fiber architecture, are not homogeneous materials like metals and are very susceptible to design features and processing technology variations. Composites are often analyzed as materials that provide enhanced strength to weight ratios, ignoring the impact of processing on performance. The focus of our research work in intelligent decision support tools for composites focuses on the conceptual design stages. There are a number of computing tools for analyzing composite structures based on finite element or finite difference methods and others that determine ply draping and lay-up. There are few tools which assist the design engineer at the conceptual phase where many of the critical affordability drivers are established. Our work has focused on the redesign of existing metal assemblies using composites because this activity is more knowledge rich than starting a design from scratch. The replacement of metal assemblies is also the dominant application area for composites and thus is highly leveraged for decision support assistance