Process FEM simulation of fiber patch placement laminates with a flexible foam-based gripper

The fiber patch placement (FPP) technology enables the automated manufacturing of complex-shaped components. However, placement defects such as bridging and wrinkling may occur during the deposition of patches onto the tool surface, which are typically unacceptable in high-performance applications. To analyze and prevent such defects, this study investigated the patch placement process using finite element (FE) simulations. Various obstacle geometries were designed to deliberately induce wrinkling, and these scenarios were subsequently simulated. Furthermore, simulations and experimental placements were carried out on an aerospace demonstrator. The simulation results were validated using 3D scan data, and typical placement defects were successfully replicated in the numerical model. The maximum deviation between scanned and simulated patches was 4.49 mm, corresponding to only 3% of the patch’s short edge length. This confirms the suitability of the approach for capturing key defect mechanisms. The placement behavior of the FPP technology has not yet been investigated using simulations validated with 3D scan data. The findings contribute to a deeper understanding of defect formation mechanisms—particularly wrinkling and bridging—under defined placement conditions. This work provides a foundation for predictive process optimization and the development of defect-preventing placement strategies for complex geometries.