Automated Fibre Placement (AFP) allows for efficient deposition of composite prepreg materials at large scale in a reliable and reproducible way, while keeping human effort to a minimum. However, the technique is not perfectly suited to manufacturing small/medium parts with complex geometries. Deviation between as-designed and as-manufactured parts is almost inevitable, as is the occurrence of process-induced defects. In this study, an alternative design and manufacturing process is proposed. Instead of depositing composite tapes directly onto the complex mould, a flat tailored preform made from steered fibre tows is created first, and then the flat preform is subsequently formed into a 3D complex shape. The fibre path in the flat tailored preform is derived from a new virtual ‘un-forming’ process of a complex 3D part design with target fibre paths. To demonstrate the process, a small doubly curved composite part was un-formed. Fibre-steered tailored preforms were created using the continuous tow shearing (CTS) technique and then formed into the target shape using double diaphragm forming. The as-manufactured part was compared with the as-designed part as well as a part manufactured from straight fibre prepreg. The results demonstrated the feasibility of the virtual un-forming process and the potential of proposed manufacturing route.

自动纤维铺放 (AFP) 允许以可靠且可重复的方式大规模高效沉积复合预浸料，同时最大限度地减少人力。然而，该技术并不完全适合制造具有复杂几何形状的中小型零件。设计和制造的零件之间的偏差几乎是不可避免的，过程引起的缺陷的发生也是如此。在这项研究中，提出了一种替代设计和制造工艺。不是将复合带直接沉积在复杂的模具上，而是首先创建由导向纤维束制成的平面定制预制件，然后将平面预制件成型为 3D 复杂形状。平面定制预制件中的纤维路径源自具有目标纤维路径的复杂 3D 零件设计的新虚拟“未成形”过程。为了演示该过程，未成型一个小的双弯曲复合部件。使用连续丝束剪切 (CTS) 技术创建纤维导向的定制预制件，然后使用双隔膜成型将其成型为目标形状。将制造的零件与设计的零件以及由直纤维预浸料制成的零件进行比较。结果证明了虚拟未成形过程的可行性和拟议制造路线的潜力。使用连续丝束剪切 (CTS) 技术创建纤维导向的定制预制件，然后使用双隔膜成型将其成型为目标形状。将制造的零件与设计的零件以及由直纤维预浸料制成的零件进行比较。结果证明了虚拟未成形过程的可行性和拟议制造路线的潜力。使用连续丝束剪切 (CTS) 技术创建纤维导向的定制预制件，然后使用双隔膜成型将其成型为目标形状。将制造的零件与设计的零件以及由直纤维预浸料制成的零件进行比较。结果证明了虚拟未成形过程的可行性和拟议制造路线的潜力。