Optimisation of a composite pressure vessel dome using non-geodesic tow paths and automated fibre placement manufacturing

Filament winding lacks the flexibility to produce composite pressure vessels with highly optimised thickness and fibre angles. Automated fibre placement can overcome this limitation using its selective material placement capability. In this work, two dome thickness optimisation strategies are introduced and evaluated for mass reduction and manufacturability. Additionally, fifteen non-geodesic fibre paths were examined using finite element analysis (FEA). The combined thickness and fibre angle optimised domes averaged a 48.94 % improvement in structural efficiency from the baseline. A demonstrator was manufactured, and thickness and fibre angle were measured with average differences of 3.45 % and 1.86 % from the simulations. Finally, hydrostatic pressure testing was performed to validate the FEA. • Automated fibre placement was used to manufacture a dome with non-geodesic tows. • Dome thickness was optimised using ply drops for improved mass and manufacturing. • Non-geodesic fibre paths were effectively used with geodesic domes. • Design optimisation achieved a mean 48.94 % improvement in structural efficiency.