Abstract: Systems and methods are provided for composite part design. One embodiment is an apparatus that designs a composite part. The apparatus includes a controller configured to generate a design for the part. The controller subdivides the part into blocks that each comprise a contiguous stack of layers within the part, identifies rules that constrain how layers that have different fiber orientations are stacked within the part, generates a guide for a block that prescribes a fiber orientation for each layer of the block, and identifies sublaminates comprising that are compatible with the guide for the block. The controller subdivides the part into panels, and selects one of the compatible sublaminates for one of the panels of the block, based on compatible sublaminates for neighboring panels.

Abstract: A method and apparatus for ply blending. A desired thickness and a desired stiffness distribution for a composite structure are received. A model of the composite structure is split into a plurality of panels. Lamination parameters and a quantity of plies for each panel of the plurality of panels are determined using the desired thickness and the desired stiffness distribution for the composite structure. Ply shapes for each ply of the plurality of panels are determined using an objective function. A fiber angle is determined for each ply of the plurality of panels. Each ply of a first half of a panel of the plurality of panels has a different fiber angle value than each other ply of the first half of the panel.

Abstract: A composite laminate is presented. The composite laminate comprises a plurality of plies having non-traditional angles. Each of the plurality of plies has a respective shape configured to minimize a total length of the ply boundary over all of the plurality of plies. The composite laminate has a stiffness equal to a desired stiffness of a traditional composite laminate.

Abstract: Methods for optimizing fiber placement programming for use in automated manufacture of steered-fiber composite laminates. The optimization methods are implemented in software capable of optimally translating steered-fiber laminate definitions in fiber placement code for manufacturing steered-fiber laminates without overlaps. The optimization is set up to take into account manufacturing constraints, such as minimum cut length, minimum steering radius, and fiber straightening due to steering. This software includes both geometry and optimization and will take the aforementioned issues into account by optimizing the direction of lay down and the location and sequence of cutting and adding individual tows.

Abstract: Systems and methods are provided for composite part design. One embodiment is an apparatus that designs a composite part. The apparatus includes a controller configured to generate a design for the part. The controller subdivides the part into blocks that each comprise a contiguous stack of layers within the part, identifies rules that constrain how layers that have different fiber orientations are stacked within the part, generates a guide for a block that prescribes a fiber orientation for each layer of the block, and identifies sublaminates comprising that are compatible with the guide for the block. The controller subdivides the part into panels, and selects one of the compatible sublaminates for one of the panels of the block, based on compatible sublaminates for neighboring panels. The apparatus also includes a memory configured to store the design for use by an Automated Fiber Placement (AFP) machine constructing the part.

Abstract: A composite laminate is presented. The composite laminate comprises a plurality of plies having non-traditional angles. Each of the plurality of plies has a respective shape configured to minimize a total length of the ply boundary over all of the plurality of plies. The composite laminate has a stiffness equal to a desired stiffness of a traditional composite laminate.

Abstract: A method and apparatus for ply blending. A desired thickness and a desired stiffness distribution for a composite structure are received. A model of the composite structure is split into a plurality of panels. Lamination parameters and a quantity of plies for each panel of the plurality of panels are determined using the desired thickness and the desired stiffness distribution for the composite structure. Ply shapes for each ply of the plurality of panels are determined using an objective function. A fiber angle is determined for each ply of the plurality of panels. Each ply of a first half of a panel of the plurality of panels has a different fiber angle value than each other ply of the first half of the panel.

Abstract: Methods for optimizing fiber placement programming for use in automated manufacture of steered-fiber composite laminates. The optimization methods are implemented in software capable of optimally translating steered-fiber laminate definitions in fiber placement code for manufacturing steered-fiber laminates without overlaps. The optimization is set up to take into account manufacturing constraints, such as minimum cut length, minimum steering radius, and fiber straightening due to steering. This software includes both geometry and optimization and will take the aforementioned issues into account by optimizing the direction of lay down and the location and sequence of cutting and adding individual tows.