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Tailored fibre placement (TFP) is an embroidery-based technology that allows the fibre tows to be placed exactly where they are most needed for structural performance and stitched into position on a compatible textile or polymer substrate. In this study commingled carbon-nylon fibre tows were utilised to produce thermoplastic cross-ply net-shaped preforms using TFP. Four TFP composite plaques were manufactured; baseline (blank), machined-hole, tailored-hole-1 and tailored-hole-2. Steering the tows was used to create the hole in tailored-hole-1 and tailored-hole-2. In comparison to the design of tailored-hole-1, a different fibre trajectory, with a circular reinforcement around the hole, was suggested for the tailored-hole-2. Fibre volume fraction, optical microscopy, X-ray-CT scans, tensile and open-hole tests were carried out. With the exception of the baseline sample, the modified design of tailored-hole-2 composite exhibited the highest axial strength and modulus compared to the machined-hole and tailored-hole-1 composites. Only the tailored-hole-2 specimens exhibited less than 10% reduction of the notched strength compared to the un-notched strength. This study highlights the importance of the stress/load-paths and associated fibre-orientations. While TFP can be an extremely valuable design tool for composite preforms and resulting structural components, a deep understanding of stress distributions is inevitable to achieve optimal TFP-design.

Damage initiation and evolution of three-dimensional (3D) orthogonal woven carbon fibre composite (3DOWC) is investigated experimentally and numerically. Meso-scale homogenisation of the representative volume element (RVE) is utilised to predict the elastic properties, simulate damage initiation and evolution when loaded in tension. The effect of intra-yarns transverse cracking and shear diffused damage on the in-plane transverse modulus and shear modulus is investigated while one failure criterion is introduced to simulate the matrix damage. The proposed model relies on two major assumptions. First, the effect of the binder yarns, on the in-plane properties, is neglected, so the 3DOWC unit cell can be approximated as a (0°/90°) cross-ply laminate. Second, a micro-mechanics based damage approach is used at the meso-scale, so damage indicators can be correlated, explicitly, to the density of cracks within the material. Results from the simulated RVE are validated against experimental results along the warp (0° direction) and weft (90° direction). This approach paves the road for more predictive models as damage evolution laws are obtained from micro mechanical considerations and rely on few well-defined material parameters. This largely differs from classical damage mechanics approaches in which the evolution law is obtained by retrofitting experimental observations.