Composite structures play an important role in realising resource-efficient products. Their high lightweight potential and improved manufacturing technologies lead to an increased use in high-volume products. However, especially during the design and development of high-volume products, the consideration of uncertainties is essential to guarantee the final product quality. In this context, the use of modern lightweight materials, such as fibre reinforced plastics (FRP), leads to new challenges. This is due to their high number of design parameters, which are subject to deviations from their nominal values. Deviating parameters, e.g. ply angles and thicknesses, influence the manufacturing process as well as the structural behaviour of a composite part. To consider the deviating design parameters during the design process, a new tolerance optimisation approach is presented, defining tolerance values for laminate design parameters, while ensuring the functionality of the composite structure. To reduce the computational effort, metamodels are used during this optimisation to replace finite element simulations. The proposed approach is applied to a use case with different key functions to show its applicability and benefits.

复合结构在实现资源节约型产品方面起着重要作用。它们的轻量级潜力和改进的制造技术导致大量产品的使用增加。但是，尤其是在大批量产品的设计和开发过程中，不确定性的考虑对于保证最终产品的质量至关重要。在这种情况下，使用现代轻质材料，例如纤维增强塑料（FRP），带来了新的挑战。这是由于其大量的设计参数，这些参数可能会偏离其标称值。偏差参数（例如层角度和厚度）会影响制造过程以及复合零件的结构性能。为了在设计过程中考虑偏离的设计参数，提出了一种新的公差优化方法，该方法定义了层压板设计参数的公差值，同时确保了复合结构的功能。为了减少计算量，在优化过程中使用了元模型来代替有限元模拟。所提出的方法适用于具有不同关键功能的用例，以显示其适用性和优势。