A new interactive design method for carbon fibres laminate component

Abstract Carbon fibre is the most common reinforcing phase in composite materials. However, it is difficult to determine the performance parameters of a monofilament. This paper provides an efficient method for performing the global layup optimization of composite laminates, considering the relationship between material characteristics and process parameters. In particular, a new method is proposed that, by integrating commercial tools, can support designers in the design and construction of carbon fibre components. The approach involves four functional groups that interact with each other: requirements and specifications, material definition, process implementation, and design and simulation. The idea is to create a continuous process to realize continuous product optimization. The approach was applied to the optimization of the front wing of a Formula 4 vehicle. After the validation method phase, through a comparison between real data and numerical simulations, product optimization was conducted. Different optimized solutions were obtained, and the solution minimizing the mass but ‘allowing the vehicle to bear stress and strain values within the required limits was chosen. This methodology can be applied to support the designer during both the early design phase and the optimization phase of laminated products.