Design Optimization of a Braided Roof Frame Reinforcement by Process-Integrated Local Customization of Component Properties

In order to use the full potential of fiber-reinforced composite materials, load-compliant fiber architecture and suitable manufacturing technologies are essential. Therefore, multiple approaches to enable customized braided structures for highly stressed structural profiles in high volume applications are introduced and resulting design possibilities for generic parts are described. A methodology for component optimization considering manufacturing restrictions arising from the introduced customization techniques is proposed and applied to an automotive roof frame reinforcement serving as an example use case. Starting from an initial design based on a conventional triaxial braid, high-potential variants are derived by means of finite element simulation. Experimental validation confirms substantial improvements regarding lightweight and cost potential for the component’s main load case by applying the introduced process approaches.