A compact yet flexible design space for large-scale nonperiodic 3D woven composites based on a weighted game for generating candidate tow architectures

Three-dimensional non-periodic woven composite preforms have sufficient design flexibility that tows can be aligned along principal loading paths even in shaped structural components with detailed local features. While this promises competitive performance, the feasible design space is combinatorially large, far beyond exhaustive search. Seeking a design space that is compact and easily searched yet can span the full potential of 3D weaving, we propose a method for generating candidate designs called the Background Vector Method (BVM) which treats weaving tows as agents in a game competing to match background vectors derived from different design requirements. The BVM generates candidate designs that adapt local architecture to global design goals by adjusting scalar weights. A manufacturing-based parameterization assures fabricability. The scope of possible designs and the speed of the BVM are illustrated by re-creating common periodic 3D weaving patterns and novel complex non-periodic architectures, with a route demonstrated to forming cavities, ducts, and other open volumes. How the BVM might be incorporated within an optimization algorithm is outlined and pathways are shown for systematically enlarging the design space as individual design problems may require.