An integral process model for high precision composite forming

High precision composite forming implies control of the fibre orientation, residual stresses and wrinkling in the product to be manufactured. Finite Element based process simulations can assist in achieving this right-first-time manufacturing. A first order approximation of the full manufacturing process is presented in a three-step approach: a multilayer Finite Element drape simulation, a micromechanics based stiffness and stress prediction and a Finite Element trimming and spring-back prediction. A wing leading edge stiffener is presented as a validation exercise, based on which the future research topics in Composite Forming are discussed.