RTM process Interoperable Digital Twin with process defect predictions

Abstract The CAELESTIS project aims to establish an advanced Interoperable Simulation Ecosystem (ISE) that integrates product design, distributed engineering teams, and manufacturing experts to accelerate the development of next-generation aircraft. Central to CAELESTIS is the deployment of high-fidelity digital twins, facilitating accurate predictions throughout the product development cycle, including processes like automated fiber placement (AFP), laser powder bed fusion (L-PBF), and resin transfer molding (RTM). This deliverable focuses on the RTM and L-PBF Digital Twins within CAELESTIS, detailing the modeling strategies for manufacturing simulations, particularly emphasizing the fan outlet guide vane (FOGV) use case. The document elaborates on the meso-scale strategy developed for predicting void generation during RTM, incorporating bi-phasic computational fluid dynamics (CFD) simulations and PBF analysis of metallic inserts. Additionally, it outlines RTM process models from input data to distortion analysis, showcasing preliminary results.