12/10/2026
How accurately can we predict the geometry of a coreless wound fiber structure before it is built?
Coreless filament winding (CFW) creates lightweight fiber-polymer composite structures without conventional molds. Without a mold, the final geometry emerges from how the fibers interact with each other during winding, making it difficult to predict digitally.
In our new paper, “Bridging physical and digital domains of coreless wound fibrous structures: Benchmarking a simulation method,” we investigate this gap between the digital and physical domains by benchmarking a fast simulation method designed to provide feedback during early-stage design.
→ 34 specimens were fabricated and monitored, varying six design and fabrication parameters
→ Each specimen was laser-scanned after every wound fiber segment, allowing us to track how the geometry developed step by step
→ Single and Dual-robot winding setups were tested
→ On average, the simulation overestimated fiber displacement by about 20 mm
→ For 73% of the specimens, the simulation predicted exactly the same number of fiber intersection points as observed in the physical specimen
Congratulations to first author Rebeca Duque Estrada () and co-authors Laura Balangé, Christoph Zechmeister, Valentin Noah Hartmann, Fabian Kannenberg, Marc Toussaint, Volker Schwieger, and Achim Menges.
This research was funded by the Deutsche Forschungsgemeinschaft (DFG, ) - German Research Foundation under Germany’s Excellence Strategy EXC 2120/1390831618.
The open-access paper can be read through the following link:
https://doi.org/10.1093/jcde/qwag031
© Image credits: Duque Estrada et al. (2026)