Planar fibre winding for topological optimized composite structures

Conventional manufacturing techniques for composites are constrained by the shell design realized from laminated materials. The layer-wise architecture limits their use in complex 3D geometries and leads to uneven structural performance in multi-axial load scenarios. This study introduces a novel planar fibre-winding process for manufacturing topologically optimized composite structures. The proposed method utilizes a continuous process where a carbon fibre roving is wound onto a complex 3D printed winding core. This approach enables the creation of a truss-like structure that closely follows the optimal load paths. The winding process is automated using a 3-axis gantry system, allowing precise fibre placement to form spatially complex structures. The mechanical performance of a complex wound structures was evaluated against traditionally milled aluminium parts. Tensile testing of dry rovings and composite samples provide insights into the effects of process-induced damage on the mechanical performance of the composites. Significant performance improvements compared to conventional metal component design is achieved. The composite structures showed a 55% reduction in weight compared to milled aluminium components, while achieving a 160% increase in specific stiffness in out-of-plane bending tests. The process also demonstrates high reproducibility and minimized material waste. The advanced fibre-winding process offers a promising composite manufacturing technique.