A novel parametric modeling method for 3D needled composites considering mesostructure characteristics

The mesostructure of three-dimensional (3D) needled composites is highly complex, making it challenging for traditional modeling approaches to balance mesostructural fidelity with computational efficiency. To address this issue, this paper proposes a novel parametric modeling method that considers the key mesostructure characteristics of 3D needled composites. Guided by the deflection law of the needled region, the original layers, needled fiber bundles, and the deflected structures are uniformly represented in the model. This approach retains the critical mesostructure characteristics while reducing computation time by two orders of magnitude compared to the high-fidelity model. The reliability of the prediction results is further validated through experimental comparison using the composites prepared from T800 twill woven, short-chopped fiber felt, and phenolic resin. Moreover, the modeling method is independent of specific needling process parameters, demonstrating strong generality. Overall, the proposed parametric modeling method provides an efficient and accurate tool for predicting performance and optimizing the structure of 3D needled composites.