Forming the Future: A Digital Approach to Simulating Thermoplastic Manufacturing

Abstract

This thesis develops a digital framework for simulating and validating thermoplastic composite manufacturing processes, focusing on reducing the time associated with new product development. Using Finite Element Analysis (FEA) software (SimSof) and high-precision 3D scanning tools (ScanSof), the research introduces a geometric similarity metric to quantify deviations between simulated and real-world parts. By aligning simulations with production data, the study aims to replace costly physical trials with reliable digital models, accelerating customer onboarding and improving manufacturing efficiency.

Key contributions include establishing a systematic pipeline for integrating simulation tools into Oribi Composites’ workflow, defining critical parameters such as laminate width, material card accuracy, and mesh size, and validating their impact on simulation accuracy. Results demonstrate that accurate material modeling and parameter selection significantly enhance digital twin accuracy, while mesh size has minimal influence, allowing for computational cost savings. The research also highlights challenges in replicating real-world conditions digitally, including inconsistent material cards, and limited control over pressure profiles. Despite these limitations, the study proves that simulations can reliably predict manufacturable designs within customer tolerances, reducing reliance on physical iterations.