Stacking sequences in composite laminates through design optimization

Composites are experiencing a new era. The spatial resolution at which is to date possible to build up complex architectured microstructures through additive manufacturing-based and sintering of powder metals 3D printing techniques, as well as the recent improvements in both filament winding and automated fiber deposition processes, are opening new unforeseeable scenarios for applying optimization strategies to the design of high-performance structures and metamaterials that could previously be only theoretically conceived. Motivated by these new possibilities, the present work, by combining computational methods, analytical approaches and experimental analysis, shows how finite element Design Optimization algorithms can be ad hoc rewritten by identifying as design variables the orientation of the reinforcing fibers in each ply of a layered structure for redesigning fiber-reinforced composites exhibiting at the same time high stiffness and toughening, two features generally in competition each other. To highlight the flexibility and the effectiveness of the proposed strategy, after a brief recalling of the essential theoretical remarks and the implemented procedure, selected example applications are finally illustrated on laminated plates under different boundary conditions, cylindrical layered shells with varying curvature subjected to point loads and composite tubes made of carbon fiber-reinforced polymers, recently employed as structural components in advanced aerospace engineering applications.

Automated summary

Composites are entering a new era with advancements in additive manufacturing, sintering of powder metals, filament winding, and automated fiber deposition processes. Design optimization algorithms are being rewritten to include the orientation of reinforcing fibers in each ply for redesigning fiber-reinforced composites with high stiffness and toughening. The flexibility and effectiveness of this strategy are demonstrated through various applications on laminated plates, layered shells, and composite tubes in aerospace engineering.