Virtual Process Chain

Our Virtual Process Chain seamlessly connects the crucial steps product design, manufacturing validation, and engineering for the virtual product development with plastics, fiber-reinforced composites, and hybrids.

A digital product development cycle enables the close interaction between design, engineering, and manufacturing validation through a digital twin of the manufacturing process. Based on this, the know-how on the part to be manufactured is significantly increased already in the early phases of the development cycle and the risk for expensive and laborious design revision in later phases is significantly decreased.

We support you with digital product development cycles through our Virtual Process Chain, which starts with the definition of a concept and results in an optimized part or assembly ready to be manufactured. Along the virtual process chain, a digital twin of the production process predicts manufacturability as well as manufacturing effects. The predicted manufacturing effects are retained and considered in downstream simulations. Based on this, the prediction accuracy of warpage and structural simulation is increased significantly.


Design & Optimization

The smart application of plastics, fiber-reinforced composites, and hybrids require a material-specific and tailored design, to fully exploit their lightweight potential. We support you in designing, optimizing, and developing your innovative lightweight structures.


Process Simulation

The simulation of manufacturing processes is a powerful tool, which enables virtual manufacturing validation for a specific design without any real-world manufacturing piloting. Moreover, manufacturing effects, such as the resulting fiber structure, are predicted and considered in downstream simulation approaches to improve their prediction accuracy.


Warpage Simulation

Manufacturing of composites, plastics, and hybrids is often accompanied by process-induced deformations (PIDs), such as spring-in or warpage. Through thermomechanical analyses of the part cooling and solidification, these dimensional instabilities, as well as residual stresses, are predicted.


Structural Simulation

The final part needs to fulfill load requirements. These can be virtually assured by structural analyses. The structural behavior of fiber-reinforced composites, however, is distinctively influenced by manufacturing effects, which are predicted and considered through our Virtual Process Chain.

Our functional Virtual Process Chain is based on data transfer between the different simulation steps through mapping and homogenization approaches. Based on this, state variables such as fiber orientation or fiber volume content predicted by process simulation are retained and transferred to warpage and structural simulations. We conduct this step with our product SimuChain, which exports relevant state variables into a neutral exchange format, maps the results from the source to the target mesh, and creates homogenized material cards within ABAQUS.

For our Virtual Process Chain, we capture processing technologies relevant for large volume production. Here, we rely on a mixture of state-of-the-art and self-developed approaches. State-of-the-art approaches are used, wherever it is sufficient. In contrast, we use self-developed add-ons, wherever state-of-the-art is not sufficient.

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