Predictive Composite Integrated Shaping (PRECIS)

The Navyís increasing demand for lightweight, high-performance thermoplastic composite structures requires a scalable, defect-minimizing manufacturing process to replace traditional labor-intensive hand layup methods. GreenSight proposes PRECIS (Predictive Composite Integrated Shaping). This advanced thermoforming optimization framework integrates predictive geometric modeling, UV mapping, and automated process optimization to enhance the manufacturability of complex aerospace composite components. PRECIS proactively identifies and mitigates wrinkle-prone areas before forming, ensuring optimal material flow, uniform deformation, and tighter tolerances. Our Phase I effort will validate PRECIS by developing and refining predictive simulations, selecting optimal thermoplastic composite pre-pregs, and conducting forming trials on two representative aerospace components. In tensile, flexural, and compression tests, mechanical properties will be validated using ASTM-standard testing to confirm that formed parts meet or exceed 50% of the parent material strength. Successful implementation will enable the Navy to reduce composite manufacturing costs, improve production rates, and enhance part quality, supporting high-rate, low-defect thermoplastic composite production for next-generation defense applications.