In order to use the full potential of fiber-reinforced composite materials, load-compliant fiber architecture and suitable manufacturing technologies are essential. Therefore, multiple approaches to enable customized braided structures for highly stressed structural profiles in high volume applications are introduced and resulting design possibilities for generic parts are described. A methodology for component optimization considering manufacturing restrictions arising from the introduced customization techniques is proposed and applied to an automotive roof frame reinforcement serving as an example use case. Starting from an initial design based on a conventional triaxial braid, high-potential variants are derived by means of finite element simulation. Experimental validation confirms substantial improvements regarding lightweight and cost potential for the component’s main load case by applying the introduced process approaches.

为了充分发挥纤维增强复合材料的潜力，必须符合负荷要求的纤维架构和合适的制造技术。因此，介绍了在高容量应用中实现高应力结构轮廓的定制编织结构的多种方法，并介绍了通用零件的最终设计可能性。提出了一种考虑到由引入的定制技术引起的制造限制的组件优化方法，并将其应用于作为示例用例的汽车车顶框架加固。从基于常规三轴编织物的初始设计开始，借助有限元模拟得出高电势变量。