Press forming of multi-layer thermoplastic composite laminates is a fast and cost-effective method to produce thin shelled products. This paper shows that virtual forming provides designers with a tool to determine and to optimize the formability of these composite products. Forming simulations identify critical spots in the product design at an early stage and reduce costly product development times. Accurate characterization of the highly anisotropic composite materials is necessary for realistic forming predictions. Forming simulations of a thermoplastic multi-layer UD/PEKK and woven 8HS/PPS laminates are presented and validated against corresponding press trials. Fibre distribution and wrinkling patterns were compared and the results show good agreement.
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