Leveraging real 3D geometries of manufactured materials and components is a game-changer for precise modelling and simulations. In practical manufacturing, parts often deviate significantly from idealised designs, impacting vital mechanical properties like stiffness, strength, failure behaviour, and long-term durability. This variation is particularly pronounced in additive manufacturing, especially when dealing with composite materials due to their intricate internal structures.

New Frontier Technologies have the capability to create digital twins of any component, not just those we manufacture, to provide you with a better understand of its composition and performance.

For one of our clients, we constructed a detailed 3D mesh that faithfully replicated the geometry, accounting for any geometric variations or defects such as surface dents. Then, we mapped the fibre orientation values locally to each element. Material properties were assigned, and we subjected the part to a tensile load. The simulation results offer invaluable insights into how the structure responds to loading, revealing local variations in stress and strain. Monitoring overall behaviour allowed us to pinpoint potential stiffness and strength limitations, identifying areas of possible failure and provide advice on future design improvements.