A novel computational framework for structural optimization with patched laminates

Fiber patch placement (FPP) is a manufacturing technique for discrete variable stiffness composites. In the FPP approach, a structural component is assembled from a multitude of discrete fiber patches. However, due to the discontinuous fibers at patch edges, complex stress distributions occur. To date, a holistic FPP design framework that combines a tailored patch placement method with a dedicated mechanical model for the analysis of patched laminates does not exist. This article introduces a novel approach for the design of fiber patched laminates. It is based on the sequential placement of patches on a finite element shell mesh, using a critical element and angle selection routine in order to optimally locate and orientate fiber patches. They are added to the 3D mesh by employing a highly efficient kinematic draping algorithm. Strength-critical regions of the resulting fiber patched laminates are identified by state-of-the-art finite element analysis and extracted to a shear-lag–based mechanical submodel dedicated to the detailed analysis of patched laminates. The patch placement routine terminates once all design optimization criteria are met. The efficiency of applying optimized patch reinforcements on a continuous fiber-reinforced base laminate is demonstrated using the example of an individualized biomedical component. The work at hand presents the first patched laminate design framework combining a patch placement strategy coupled with a dedicated mechanical model. As a consequence, a substantial progress in the design of patch laminated structures is achieved.