Topology-based parametric modeling of three-dimensional hexagonal braids for advanced composite structures

Three-dimensional hexagonal braiding technology is an advanced method with significant potential for producing geometrically complex, large-scale braided fabrics. However, efficient geometric modeling of such intricate braid architectures remains challenging. This article presents a topology-based parametric modeling framework to effectively link three-dimensional hexagonal braiding process parameters to resultant fabric structures. The core innovation is a modeling tool that swiftly generates the yarn network topology and complete three-dimensional geometry of braids based on specified production conditions without restrictions on the number of layers. We utilize this tool to simulate diverse braiding patterns and systematically assess the influence of key process variables on the emerging fabric configuration. We identify a unit cell motif in multilayered versions that may provide insights into mechanical properties. Then, to extend the tool’s utility, we introduce a novel concentric circle projection technique that enables structural modeling of hollow three-dimensional hexagonal braided tubes critical for high-performance composites. The versatility of this parameterization scheme could bolster the development of novel braid-derived engineering materials. Finally, tubular braided preforms and lamellar braided preforms were produced to verify the accuracy of the parametric modeling algorithm.