High-fidelity simulation tools have significant potential to support composite aircraft sustainment, though further study is required on incorporating the complex impact damage field. In this paper, compressive residual strength assessment is investigated using the high-fidelity computational tool BSAMTM. The experimental impact damage was mapped and modelled at a high-fidelity level, which included ply-by-ply definition of the geometry of the impact indentation, fibre fracture in the plies and delamination in ply interfaces. It was shown that applying a small lateral displacement or ‘pseudo-impact’ step was highly effective in generating matrix cracks in the impact region, which provided a suitably realistic representation of the interconnected damage map through-the-thickness. It was found that inclusion of all damage modes in the post-image damage map at a high-fidelity definition was essential due to the strong degree of interaction between damage modes. The results support improved sustainment of defence platforms, through enhanced predictive capability and understanding.

Considering manufacturing expertise during the early stages of design can be of great benefit. Such information can greatly improve not only the quality of a design, but it can also ensure the generation of an easily manufactured design. This, in turn, can lower the final cost of the designed product. By evaluating how easily an evolving conceptual design can be made, potential hazards can be avoided before any detailed design efforts commence. The conceptual manufacturing planning requisite to such an evaluation is the focus of this paper. A domain-independent strategy for conceptual manufacturing planning is presented. A task-structure analysis of this strategy shows its domain independence. A specific implementation of this strategy for polymer composites manufacturing planning (Socharis) is discussed. The high-level implementation details of Socharis are presented as instantiations of the conceptual manufacturing planning strategy. Finally, the validity of the planning strategy and the utility of Socharis are assessed.