Numerical investigations were conducted to explore the mechanical response of hybrid layered continuous–discontinuous tape composites focusing on damage initiation and ultimate strength under both tensile and bending loads. These composites combine layers of continuous unidirectional tapes with layers of randomly oriented short (discontinuous) tapes. A series of laminated specimens was analyzed, representing various strategies to create hybrid combinations as well as the limit cases of pure continuous and pure discontinuous tapes. The hybrid architectures consist of different stacking sequences and varying ratios of continuous and discontinuous plies. Detailed mesoscale simulations were performed utilizing a finite element model that explicitly incorporates the ply-level arrangements of both continuous and discontinuous plies. By means of numerical homogenization, the effective elastic stiffness and strength of each configuration were determined, enabling the establishment of scaling laws for these properties with respect to spatial variability and the ratio of continuous to discontinuous tape content. These findings serve as a roadmap for optimizing the blend of these two types of tape to meet specific mechanical performance targets, thereby advancing the development of more sustainable and high-performing composites.

Chopped Tape Thermoplastic Composites (CTTCs) offer high formability and performance for complex-shaped components in the aerospace and automotive industries. However, the mesoscopic discontinuity leads to spatial variabilities and correspondingly high scatter in the elastic properties of CTTCs due to the random orientations of chopped tapes and chopped tape-cavity edge interactions. Here we propose a new approach to investigate the effect of mould cavity edges on chopped tape orientation and hence the mechanical properties of CTTCs. Based on this approach, a Set Voronoi tessellation was implemented to represent the variability of local Young's Modulus and chopped tape-cavity edge interactions occurring during the manufacturing process. It was confirmed that the chopped tapes align along the edges, and progressively transition to a random orientation towards the middle of the specimen. The results were validated on moulded specimens and demonstrated the ability to deconvolute the edge interaction.

Discontinuous fiber composites (DFC) have properties such as notch insensitivity, short processing times, and large shaping freedom [1-3]. However, the mechanical behavior of ROT composites is less predictable compared to continuous fiber composites due to the mesoscopic heterogeneity of the material [4]. Controlling the tape alignment is a compelling approach for tailoring the mechanical properties of the ROT composites, enabling better control and prediction of the material properties such as tensile strength and stiffness [5]. However, for a successful implementation of the alignment method in industry, a fast tape alignment method is needed. In this study, a quantitative assessment has been made between three alignment methods. The methods have been evaluated in respect of the level of alignment and the manufacturing process by means of a decision-making matrix. The level of alignment of each method has been determined using computer vision on the orientation of individual tapes. The final alignment method has been selected which uses vertical mesoscopic sieves with a high aspect ratio to rotate tapes in a preferred direction during deposition. With this alignment method, ROT have been aligned at -45˚, 0˚, and +45˚ with respect to the loading direction. With these alignment tools, CF/PEEK ROT have been deposited inside a cavity followed by a consolidation cycle at 45 bar and 385˚C. The effect of alignment was examined by comparing the mechanical response of samples with: ROT, being longitudinally aligned, and a laminate of [+45˚,-45˚]s aligned pseudo-layers. The results of tensile tests showed that by aligning tapes in the longitudinal direction, the average tensile stiffness and strength increased by 145% (from 32.5 to 79.7 GPa) and 96% (from 202 to 396 MPa) respectively compared to randomly orientated tapes. These results show the potential gain in material properties and the ease of implementation of the method.

Discontinuous tape composites have considerable attention due to their high formability and tailorable structures. Despite their advantages, this discontinuity leads to complex structures and makes it difficult to predict their mechanical properties. On the other hand, they have high orientational and dimensional sensitivity, which causes spatial variability and complexity in the structure to predict the mechanical properties. This spatial variability is also related to the mould cavity. A constitutive model was improved to explain the relationship between DT orientations and the mould cavity. According to the modelling technique, a random DT distribution was generated by Random Sequential Adsorption then, the Set Voronoi Tessellation was implemented to obtain DT layers. Afterwards, the Classical Laminate Theory and Finite Element Method were applied to compare the virtual net-shaped DT specimens. The results of both methods showed high stiffness at the edges of the specimens.