Innovative Design and Manufacturing Techniques for Fiber Reinforced Plastic Components

This paper covers new and paradigm changing findings in analysis, optimization, design and manufacturing of endless fiber composites as developed by an international group of experts in research and industry inspired and driven by Prof. em. Stephen Tsai. This was presented at the 2019 Munich Lightweight Symposium and is added to the 2020 proceedings as an introduction of the application as presented by Neuhausler in this year’s symposium [7]. The fundamental finding used for the new concepts is the normalizing property of the trace of the stiffness matrix of a unidirectional ply as an invariant material property of plies and laminates. This as a basis enables the use of variable ply angles, a so-called Double-Double architecture of sub-laminates and many more. Much simpler stackings, less design rules to follow, increased strength of laminates, thinner minimum gages, simplified optimization and easier and cost-efficient manufacturing can be obtained.