We coupled our latest generative design technologies with the composites design capabilities to produce a proof of concept, featured in this month's issue of Composites World. 

The use case of interest here is the Electric Vehicle (EV) battery enclosures made with composites materials. 

DASSAULT SYSTEMES offers with its 3DEXPERIENCE Platform release R2022x the possibility to automatically generate beads on a shell that enhance its structural performance, like the eigenfrequencies, through the Generative Design solutions. Unlike Generative Design based on topology optimization, this technique does not introduce cutouts in the cover, but rather deform the surface geometry with respect to authorized orientations (emboss/deboss). As itself, it does not change the mass of the part, but improves its mechanical performances. Coupled with CATIA composite design solutions, the anisotropy of the material is then considered and proposes to the designer the right pattern of beads to make sure the goals for vibrations, displacements and strengths are respected, with SIMULIA’s Abaqus solver assessing the mechanical response at each stage of the engineering process.

Once quickly converged, the enhanced design is assessed for manufacturability through our CATIA composite forming simulation capabilities, with a quick producibility simulation of the whole stack of plies, minimizing the overall deformation in each ply to reflect sliding allowed during forming, that calculate the deformation and deviation in each ply, the sliding at the interfaces between plies as well as the instantaneous calculation of the corresponding blank shapes, providing an excellent starting point for the estimation of material quantities and the preparation of detailed simulation model.

https://www.compositesworld.com/articles/price-performance-protection-ev-battery-enclosures-part-1

Special thanks to @RR ​​​​​​​@PP ​​​​​​​@EA ​​​​​​​