Numerical Investigation of Process–Induced Structural Effects in Pressed Braided Thermoplastic Tape Composites

  • Madia, Evgenia (Dresden University of Technology - TUD)
  • Tzortzinis, Georgios (Dresden University of Technology - TUD)
  • Filippatos, Angelos (University of Patras)
  • Gude, Maik (Dresden University of Technology - TUD)

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The mechanical performance of thermoplastic composites manufactured from braided tape preforms is strongly influenced by the structural evolution occurring during processing. In pressing-based manufacturing routes using fiber-reinforced thermoplastic braided tape preforms, variations in preform architecture govern melt flow pathways, consolidation behavior, and final fiber orientation. A clearer understanding of these effects is essential for robust process design and for reducing experimental development effort. This contribution presents a numerical framework for analyzing the relationship between manufacturing parameters, braid architecture, and thermoplastic flow during pressing. Process descriptions for braiding, cutting, and stacking are implemented using analytical relations and MATLAB/Simulink-based process models to predict relevant preform characteristics such as braid angle, thickness, coverage, and porosity. Heating and transport stages are additionally modeled to estimate temperature distributions and viscosity evolution prior to consolidation. Based on the predicted preform descriptors, representative textile geometries are reconstructed in TexGen and transferred to Abaqus, where finite element simulations, employing previously validated tape properties, are performed to capture infiltration and compaction behavior during the pressing process. Complementary experimental pressing trials are conducted to support and assess the numerical results. The proposed modeling chain enables a structured evaluation of how variations in process parameters affect preform deformation, melt redistribution, and consolidation behavior in braided thermoplastic composites. Numerical results reveal the sensitivity of flow and compaction behavior to changes in braid architecture and thermal history, while experimental pressing trials provide qualitative support for the predicted trends. The framework supports systematic exploration of pressing-based manufacturing routes and contributes to a more informed process design for braided thermoplastic tape composites.