In Project FibraGen, a hybrid kinematic-finite element algorithm is used to simulate the draping of a fabric (fiber composites) over a 3D molds. Although the technique proposed in that project is super fast and satisfactory enough for hand layup fabrication processes, it cannot be employed for other fabrication methods, particularly those done by press and mold.
When more accurate results are needed where wrinkles are modeled properly, high fidelity finite element analysis is the way to go. However, this comes with a substantially higher computational cost compared to that associated with the method developed in Project FibraGen.
A key difficulty is that the standard constitutive equations (material models) do not apply to fiber-reinforced composites, as they are anisotropic materials and undergo large deformations in the fabrication processes. Thus, a new material model is required that handle such complexities.
In this project, a new anisotropic hyper-elastic material model is proposed that can model fiber composites with two anisotropic directions. Due to IP limitations, I am not able to share more about the technical/scientific details, except a few examples of this model in action.