Composite stacking sequence optimization for multi-zoned composites

A method of reducing internal ply edges in a composite laminate aerospace application having two or more zones, wherein the zones have various numbers of plies of different fiber orientations, the method comprising the steps of:

• determining the number of zones for the composite laminate aerospace application;
• determining the number of plies of each fiber orientation required in each zone;
• generating a master zone that notionally includes, for plies having each different fiber orientation, the maximum number of plies having a respective fiber orientation required in any one zone;
• sequencing the plies of the master zone using a predefined series of design rules to define a stacking sequence of plies in the master zone;
• arranging the plies of each zone based upon the stacking sequence of plies in the master zone;
• and
• providing instructions configured to at least partially direct manufacture of the composite laminate based upon an arrangement of the plies of each zone.

An apparatus for reducing internal ply edges in a composite laminate having two or more zones, wherein the zones have various numbers of plies having different properties, the apparatus comprising:

• processing circuitry for:
• (i) determining the number of plies having each property required in each zone;
• (ii) generating a master zone that notionally includes, for plies having each different property, the maximum number of plies having a respective property required in any one zone;
• (iii) sequencing the plies of the master zone using a predefined series of design rules to define a stacking sequence of plies in the master zone;
• (iv) arranging the plies of each zone based upon the stacking sequence of plies in the master zone;
• and (v) providing instructions configured to at least partially direct manufacture of the composite laminate based upon an arrangement of the plies of each zone.

A computer program product for reducing internal ply edges in a composite laminate having two or more zones, wherein the zones have various numbers of plies having different properties, the computer program product comprising a computer-readable storage medium having computer-readable program instructions stored therein, the computer-readable program portions comprising:

• a first executable portion for determining the number of plies having each property required in each zone;
• a second executable portion for generating a master zone that notionally includes, for plies having each different property, the maximum number of plies having a respective property required in any one zone;
• a third executable portion for sequencing the plies of the master zone using a predefined series of design rules to define a stacking sequence of plies in the master zone;
• a fourth executable portion for arranging the plies of each zone based upon the stacking sequence of plies in the master zone;
• and
• a fifth executable portion for providing instructions configured to at least partially direct manufacture of the composite laminate based upon an arrangement of the plies of each zone.