Methodology for Accurate Geometric Modeling of Filament Wound Structures

Filament winding (FW) is a widely used automated manufacturing method for cylindrical composite structures. However, conventional modeling approaches often rely on oversimplified geometries, neglecting essential features such as fiber overlaps and gaps, which can affect the accuracy of subsequent mechanical analysis. In this work, we present a computational methodology for the accurate geometric reconstruction of FW components, based on the numerical calculation of fiber trajectories and their automated integration into CAD models. The proposed approach provides realistic geometrical representations that capture the actual fiber paths, enabling more reliable finite element simulations. Comparative results between the proposed method and traditional modeling techniques highlight key differences in stiffness prediction, demonstrating the importance of realistic geometric input for the mechanical analysis of filament-wound structures.