Liquid Composite Molding (LCM) processes encompass a large family of composite processing methods that use a pressure difference to drive a liquid resin into a mold to saturate all the empty spaces between fibers of a stationary preform. The success in such net shape manufacturing processes is strongly correlated with the part geometry and design. Coupling LCM processing simulation tools with part design could make the manufacturing of composites more efficient. The aim of this dissertation is to present models, methodologies and frameworks to integrate the composite process simulation within the composite part design cycle.;To bridge the gap between the composite process simulations with the part design, one needs to first automate the processing parameters' selection and optimization in mold filling simulation packages. Various effective optimizers are developed to find the optimal injection/infusion scheme so that the results returned by the mold filling simulation packages can guide the part design process.;Next, approaches are developed to improve the LCM simulation workflows by combining stochastic models and frameworks with the simulation engine to address possible variability in the process. Such improved simulation methodologies will provide useful feedback to the designer on how to reduce variability in the manufacturing process within the design workspace.;To increase the efficiency of the design-simulation iteration cycle, a fast distance based model is developed to replace time intensive finite element based LCM simulation which makes it possible to provide qualitatively accurate information about the process to part designers in a very short period of time for them to modify the design to accommodate robust processing. This tool is shown to be useful in the initial stages of design when large number of permutations are inevitable.;The methodology and integration framework is exercised to provide general design coupled with simulations solutions for manufacturing of net shaped composite parts and demonstrated with an application that couples the design with optimized process models that account for variability to achieve specific objective such as in wind blade design and manufacturing.
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