Tight interaction between design, analysis and manufacturing is required to engineer a composite part. In most cases, the final part contains details and modifications that create significant differences between the design model, the analysis model, and the manufactured part. For example, dramatic, changes in fiber orientation can occur which induce wrinkling and large thickness changes. Ply drop-offs and staggers may change the laminate stack-up symmetry and balance. All of these issues can have a considerable effect on the performance of the part. This paper describes how the FiberSIM suite of CAD integrated software tools for composites can be used to address these issues. For the first time, the link between CAD software, analysis software, and manufacturing equipment makes it possible for designers, analysts and manufacturing engineers to access the CAD master model of a composite part in its to-be-manufactured state. Engineers can verify at any time during the design and manufacturing process that the part meets the performance specifications. Practical case studies from industry highlight how composite engineering is improved and risk is reduced through the use of a complete and detailed virtual prototype.
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