Fibers Im User Guide

FibersimTM User
Guide
Contents
Chapter 1: Overview/List of Packages
Introduction ───────────────────────────────────────── 1-1
List of Fibersim packages ──────────────────────────────── 1-3
About the Bundle values ───────────────────────────────── 1-4
User Guide Breakdown ────────────────────────────────── 1-5
About the Fibersim Icons ───────────────────────────────── 1-7
How Units Display in Fibersim ───────────────────────────── 1-8
Supported Units and Abbreviations ───────────────────────────── 1-8
How each CAD System Handles Units ─────────────────────────── 1-10
Fibersim Color Palette ────────────────────────────────── 1-11
Chapter 2: Basic (Functions and Interfaces)

Introduction ───────────────────────────────────────── 2-1
Basic (Application Browser) ─────────────────────────────── 2-2
Laminates ────────────────────────────────────────── 2-4
When to Define Additional Laminates ──────────────────────────── 2-5
Laminate (interface) ────────────────────────────────────── 2-6
a) Design-to-Extended Design Approach (Design Boundary) ────────────── 2-9
b) List of Zone-Based Options ──────────────────────────────── 2-11
Analysis (for both Net and Extended boundaries) ──────────────────── 2-13
Laminate Object Toolbar (with utilities) ────────────────────────── 2-17
Rosettes ────────────────────────────────────────── 2-19
Rosette Requirements ───────────────────────────────────── 2-20
Rosette Mapping Types ──────────────────────────────────── 2-21
Standard Mapping ───────────────────────────────────── 2-22
Translational Mapping ────────────────────────────────── 2-23
Radial Mapping ────────────────────────────────────── 2-25
Spine-Based Mapping ─────────────────────────────────── 2-26
Field-Based Rosettes (details) ────────────────────────────── 2-27
How to Define a Rosette ─────────────────────────────────── 2-28
Rosette User Interface ───────────────────────────────────── 2-33
Plies ───────────────────────────────────────────── 2-36
About 3D Geometry (for ply definitions) ────────────────────────── 2-37
Ply (interface) ────────────────────────────────────────── 2-38
The Ply Toolbar ─────────────────────────────────────── 2-38
Notes on Wrapped plies ───────────────────────────────── 2-42
CAD Note (NX only): Periodic Faces ────────────────────────── 2-43
Simulation tab ─────────────────────────────────────── 2-44
How a Ply’s simulation results display ───────────────────────── 2-48
Cores ──────────────────────────────────────────── 2-52
Fibersim User Guide 2

© 2018 Siemens Product Lifecycle Management Software, Inc.
Contents
Virtual Step Cores ─────────────────────────────────────── 2-53

Virtual Cores ────────────────────────────────────────── 2-55
Virtual Variable Cores ───────────────────────────────────── 2-58
Modeled Cores ───────────────────────────────────────── 2-63
Design Stations ────────────────────────────────────── 2-65
Understanding Core Sampling ──────────────────────────────── 2-66
Design Station Object ───────────────────────────────────── 2-76
Types of Core Samples ──────────────────────────────────── 2-79
Summary samples ───────────────────────────────────── 2-79
Detailed samples ───────────────────────────────────── 2-80
Laminate Rating Samples ──────────────────────────────── 2-82
Cutouts ─────────────────────────────────────────── 2-85
Darting ─────────────────────────────────────────── 2-87
Interpreting Producibility ─────────────────────────────────── 2-88
Slit Darts ───────────────────────────────────────────── 2-89
Slit Darts to Eliminate Wrinkling (Puckering) ───────────────────── 2-90
Valid Slit Dart Geometry for Wrinkling (Puckering) ───────────────── 2-93
V-Shape Darts ────────────────────────────────────────── 2-94
V-Shape Darts to Eliminate Wrinkling (Bridging) ─────────────────── 2-96
Valid V-Shape Dart Geometry for Wrinkling (Bridging) ─────────────── 2-98
Chapter 3: Advanced
Introduction ───────────────────────────────────────── 3-1
Advanced (Application Browser) ─────────────────────────────── 3-2
Design ──────────────────────────────────────────── 3-5
Zone ──────────────────────────────────────────────── 3-6
Overlay Zones ───────────────────────────────────────── 3-10
Zone Transition ───────────────────────────────────────── 3-13
Transition Extension along a Reference Curve ──────────────────── 3-19
a.) Initial Distance at Start of ZT (visual demo) ──────────────────── 3-22
b.) Incremental Distance at Start of ZT (visual demo) ──────────────── 3-24
c.) Initial Extension Distance at End (visual demo) ───────────────── 3-25
d.) Extension Distance Increment at End (visual demo) ────────────── 3-27
e.) Trimming Curves (visual demo) ─────────────────────────── 3-28
Stagger Editor ───────────────────────────────────────── 3-32
Transition Adjacency Vertex ───────────────────────────────── 3-35
Non-Tangency ─────────────────────────────────────── 3-38
Variable Length Chamfer ───────────────────────────────── 3-39
Constant Length Chamfer ──────────────────────────────── 3-40
Minimum Length Chamfer ──────────────────────────────── 3-42
Fixed Transition Chamfer ───────────────────────────────── 3-44
Minimum Course ───────────────────────────────────── 3-45
Point to Point ──────────────────────────────────────── 3-46

Contents
Construction Transition ────────────────────────────────── 3-47

Layers ────────────────────────────────────────────── 3-48
Core Layer ──────────────────────────────────────────── 3-52
Manufacturing ────────────────────────────────────── 3-54
Splice Group ────────────────────────────────────────── 3-54
Darts ─────────────────────────────────────────────── 3-57
Dart Group ─────────────────────────────────────────── 3-58
Design Station ───────────────────────────────────────── 3-60
Cutouts ───────────────────────────────────────────── 3-85
Specifications ─────────────────────────────────────── 3-62
Laminate Specifications ──────────────────────────────────── 3-62
Material Specifications ──────────────────────────────────── 3-64
Notes on Material Specifications ────────────────────────────── 3-66
Offset Specifications ───────────────────────────────────── 3-67
Advanced Positioning Options (pop-up menu) ──────────────────── 3-70
A.) Initial Offset ────────────────────────────────────── 3-71
B.) Ramp Centered Offset ──────────────────────────────── 3-72
C.) Center Based Offset ────────────────────────────────── 3-73
D.) Distributed Offset ─────────────────────────────────── 3-74
Advanced Spacing Options ─────────────────────────────── 3-75
a.) Distance Based Offset options ─────────────────────────── 3-76
b.) Total Distance Based Offset options ──────────────────────── 3-78
c.) Material Thickness Based Offset options ───────────────────── 3-79
d.) Custom Based Offset options ──────────────────────────── 3-81
e.) Material Ratio Offset ───────────────────────────────── 3-82
Stagger Profile ───────────────────────────────────────── 3-84
Laminate Regions ─────────────────────────────────────── 3-85
List of Laminate Region objects ─────────────────────────────── 3-86
Chapter 4: Wind (Interfaces)

Introduction ───────────────────────────────────────── 4-1
Objects used in wind blade production ──────────────────────── 4-2
Design ─────────────────────────────────────────────── 4-2
a) Laminate ───────────────────────────────────────── 4-2
b) Rosette ────────────────────────────────────────── 4-3
c) Layer ──────────────────────────────────────────── 4-4
d) Core Layer ───────────────────────────────────────── 4-5
Manufacturing ────────────────────────────────────────── 4-6
a) Ply ───────────────────────────────────────────── 4-6
b) Course ─────────────────────────────────────────── 4-7
c) Core ──────────────────────────────────────────── 4-8
d) Splice Group ─────────────────────────────────────── 4-9
e) Design Station ───────────────────────────────────── 4-10
4 Fibersim User Guide

Contents
f) Cutout ────────────────────────────────────────── 4-11

Course ──────────────────────────────────────────── 4-12
Wind Blade Import (utility) ─────────────────────────────── 4-16
Excel spreadsheet parameters ──────────────────────────────── 4-18
Workflow - Geometry ───────────────────────────────────── 4-19
Results - Created Geometry ───────────────────────────────── 4-20
Region Details (w/ images) ────────────────────────────────── 4-21
Leading & Trailing Edge ───────────────────────────────── 4-22
Spar Cap ────────────────────────────────────────── 4-23
Leading and Trailing Core ──────────────────────────────── 4-24
Leading and Trailing Core ──────────────────────────────── 4-25
Full Body ────────────────────────────────────────── 4-26
Chapter 5: Automated Deposition Design (ADD)

Introduction ───────────────────────────────────────── 5-1
Extended Ramp ─────────────────────────────────────── 5-2
Minimum Course Extension ─────────────────────────────── 5-4
Minimum Course Extension Utility ────────────────────────── 5-7
Minimum Course Vertex ───────────────────────────────── 5-9
Minimum Course Vertex Utility ──────────────────────────── 5-11
Stagger Origin ─────────────────────────────────────── 5-13
Chapter 6: Documentation
Introduction ───────────────────────────────────────── 6-1
Planar Cross Section ──────────────────────────────────── 6-2
3D Cross Section ────────────────────────────────────── 6-6
Definition of Minimum Distance Between Ramps ───────────────────── 6-9
Explode Laminate ──────────────────────────────────── 6-10
Flat Pattern Layout ──────────────────────────────────── 6-12
3D Text Annotations ─────────────────────────────────── 6-14
Core Sample ────────────────────────────────────────── 6-14
Ply Table ───────────────────────────────────────────── 6-17
Ply Callout ──────────────────────────────────────────── 6-19
Material Table ────────────────────────────────────────── 6-21
2D Drawings (CATIA V5 and NX Only) ──────────────────────── 6-22
Ply Book ───────────────────────────────────────────── 6-23
Ply Book Surface ──────────────────────────────────────── 6-29
Ply Table ───────────────────────────────────────────── 6-17
Chapter 7: Parametric Surface Offset (PSO) Elements

Introduction ───────────────────────────────────────── 7-1
Parametric Surface Offset utility ──────────────────────────── 7-2
Parametric Surface Offset (PSO) Surface ─────────────────────── 7-3

Contents
PSO Constant Area ───────────────────────────────────── 7-5

PSO Ramp Area ─────────────────────────────────────── 7-7
PSO Constant Rail ───────────────────────────────────── 7-9
PSO Ramp Rail ─────────────────────────────────────── 7-11
Chapter 8: Import/Export
Introduction ───────────────────────────────────────── 8-1
Import Options ─────────────────────────────────────── 8-2
Analysis – Ply ─────────────────────────────────────────── 8-2
Ansys ACP ────────────────────────────────────────── 8-6
Beta CAE ANSA ────────────────────────────────────── 8-11
CAE Exchange Format (Ply Import) ─────────────────────────── 8-13
CAE Import to Overlay Zones ────────────────────────────── 8-15
MSC Laminate Modeler Import ───────────────────────────── 8-17
NX Laminate Composites ──────────────────────────────── 8-19
Analysis - Zone ───────────────────────────────────────── 8-21
CAE Exchange Format ────────────────────────────────── 8-23
MSC SimXpert (Zone Import) ────────────────────────────── 8-25
Laser Projection ──────────────────────────────────────── 8-27
About Laser Projection ────────────────────────────────── 8-27
Import Laser Projection Data (User Interface) ──────────────────── 8-28
Fiber Placement ──────────────────────────────────────── 8-30
ACE V2 Fiber Placement Import ───────────────────────────── 8-30
Preliminary Design Interface (Import) ─────────────────────────── 8-35
Ply Import from Excel ───────────────────────────────────── 8-37
Composite Part XML Import ───────────────────────────────── 8-39
Wind Blade Design Import ────────────────────────────────── 8-41
Composite Part STEP ────────────────────────────────────── 8-44
Export Options ────────────────────────────────────── 8-45
Analysis – Ply ─────────────────────────────────────────── 8-2
Analysis – Zone ───────────────────────────────────────── 8-21
Analysis – Core Sample ──────────────────────────────────── 8-51
Flat Pattern Export ─────────────────────────────────────── 8-53
Cutting Edge ──────────────────────────────────────── 8-55
DXF ───────────────────────────────────────────── 8-58
(A)GFM-NS2 ──────────────────────────────────────── 8-61
IGES ───────────────────────────────────────────── 8-64
Optimation ───────────────────────────────────────── 8-66
JETCAM Expert ® ───────────────────────────────────── 8-69
Laser Projection ──────────────────────────────────────── 8-27
Assembly Guidance ──────────────────────────────────── 8-71
List of the other Laser export format options ───────────────────── 8-75

Contents
Defining Reference Points ──────────────────────────────── 8-76

Fiber Placement Interface ────────────────────────────────── 8-78
Fives Cincinnati – ACRAPLACE ────────────────────────────── 8-79
Fives Cincinnati – ACE V2 ──────────────────────────────── 8-82
Ingersoll ─────────────────────────────────────────── 8-84
CGTech - Vericut Composite Programming ────────────────────── 8-87
Coriolis – CAD Fiber ──────────────────────────────────── 8-89
Automated Tape Laying Interface ────────────────────────────── 8-91
Fives Cincinnati – ACE V2 ──────────────────────────────── 8-91
MikroSam ────────────────────────────────────────── 8-95
Broadgood (Tecnomatix) ─────────────────────────────────── 8-97
Preliminary Design Interface (Export) ─────────────────────────── 8-99
Ply Export to XML ─────────────────────────────────────── 8-100
Composite Part XML ───────────────────────────────────── 8-102
Composite Part STEP ────────────────────────────────────── 8-44
Chapter 9: Volume Fill

Introduction ───────────────────────────────────────── 9-1
Volume Fill Utility ───────────────────────────────────── 9-1
Details of Volume Fill Functionality ────────────────────────────── 9-3
Changes in Normal Orientation of Fill To Surface (to define volumes) ────── 9-3
Multiple Fill To surfaces ────────────────────────────────── 9-5
Highlighting options ──────────────────────────────────── 9-7
Ply simulations using Offset surfaces on by default ────────────────── 9-8
Additional full body layer is no longer generated (by default) ─────────── 9-11
Laminate Design Boundary used for layer curve assignment ─────────── 9-12
Index A: Materials and Machine Databases

Introduction ──────────────────────────────────────── 10-1
How to Edit a Database ───────────────────────────────── 10-2
Editing XML ─────────────────────────────────────────── 10-2
Adding a Material to the Database ───────────────────────────── 10-4
Deleting a Material from the Database ─────────────────────────── 10-5
Changing a Material in the Database ──────────────────────────── 10-6
Accessing a Different Material Database file ─────────────────────── 10-7
How to Edit the Defaults File ───────────────────────────────── 10-8
Integrating CATMaterials with Fibersim ────────────────────── 10-9
Addition to CATMaterials Database ───────────────────────────── 10-9
CATMaterial Members Used by Fibersim ───────────────────────── 10-12
Configuring the DBConfiguration.xml file ──────────────────────── 10-14
Materials Database Members ──────────────────────────── 10-16
Standard ──────────────────────────────────────────── 10-17
Thickness ─────────────────────────────────────────── 10-19

Contents
Architecture ──────────────────────────────────────────
10-20
Cost & Weight ─────────────────────────────────────────
10-21
Laminate Rating ───────────────────────────────────────
10-22
Mechanical Properties A ───────────────────────────────────
10-23
Mechanical Properties B ───────────────────────────────────
10-25
Custom MAT8 Properties ──────────────────────────────────
10-27
Thermal Properties ──────────────────────────────────────
10-28
Radius of Curvature ─────────────────────────────────────
10-29
Orientation Colors ──────────────────────────────────────
10-30
Line Styles ───────────────────────────────────────────
10-31
Line Thickness ────────────────────────────────────────
10-32
Custom ─────────────────────────────────────────────10-33
Machine Database Members ───────────────────────────── 10-34
Index B: Utilities
Introduction ──────────────────────────────────────── 11-1
Accessing the Utilities in Fibersim ────────────────────────────── 11-1
The Main Utilities Toolbar ─────────────────────────────── 11-2
Design Checker ───────────────────────────────────────── 11-3
Cleanup Utility (NX-specific) ──────────────────────────────── 11-19
Partial Boundary Editor ─────────────────────────────────── 11-21
Composite Sequence Manager ─────────────────────────────── 11-24
Resequence Options ─────────────────────────────────── 11-27
Object Locator ──────────────────────────────────────── 11-29
Tools > Operations ─────────────────────────────────── 11-31
Material Substitution ──────────────────────────────────── 11-32
Mirror Laminate ─────────────────────────────────────── 11-34
Zone to Layer Analysis ──────────────────────────────────── 11-36
Step Utility ─────────────────────────────────────────── 11-39
Drop-Off Order Utility ──────────────────────────────────── 11-41
Ply Drop-Off ────────────────────────────────────────── 11-43
Splice Ply ──────────────────────────────────────────── 11-46
Grid-Based Zone Maker ─────────────────────────────────── 11-48
Zone Transition Splitter ─────────────────────────────────── 11-50
Minimum Course Extension Utility ──────────────────────────── 11-52
Minimum Course Vertex Utility ────────────────────────────── 11-53
Formed Laminate Utility ─────────────────────────────────── 11-54
Flat Pattern Layout ────────────────────────────────────── 11-58
Course Generation Utility ────────────────────────────────── 11-59
Tools > Derivative Laminates ───────────────────────────── 11-61
Symmetric Laminate ───────────────────────────────────── 11-62
Merge Models ───────────────────────────────────────── 11-64
Surface Transfer ─────────────────────────────────────── 11-66

Contents
Manufacturing Laminate Creation ───────────────────────────── 11-68

2D Laminate Creation ──────────────────────────────────── 11-71
Tools > Curve Creation ───────────────────────────────── 11-73
Fiber Path Curve Creation ────────────────────────────────── 11-74
Curve Creation ──────────────────────────────────────── 11-76
IML Curve Creation ────────────────────────────────────── 11-78
Boundary Simplification ─────────────────────────────────── 11-80
Curve Offset ────────────────────────────────────────── 11-83
Tools > Surface/Solid Creation ──────────────────────────── 11-90
Parametric Surface Offset ────────────────────────────────── 11-91
Constant Surface Offset ─────────────────────────────────── 11-94
Explicit Surface Offset ──────────────────────────────────── 11-98
Ply-Based Explicit Surface Offset ───────────────────────────── 11-101
Section-Based Surface Offset ─────────────────────────────── 11-103
Parameter Thickness Location ────────────────────────────── 11-105
Zone Based Solid ────────────────────────────────────── 11-107
Stepped Solid ──────────────────────────────────────── 11-109
Index C: Tools > Options > Fibersim Options

Introduction ──────────────────────────────────────── 12-1
Display Colors ─────────────────────────────────────── 12-2
C.3 Naming Conventions ──────────────────────────────── 12-3
Components ────────────────────────────────────────── 12-3
Geometry ──────────────────────────────────────────── 12-4
Zone Text Display ──────────────────────────────────── 12-5
Flat Pattern Placement Options ──────────────────────────── 12-6
Flat Patterns Tab ──────────────────────────────────────── 12-7
Tolerances Tab ───────────────────────────────────────── 12-9
a1) Upgrade Curve Accuracy (Advanced Curvature Mode) ──────────── 12-12
a2) Benefits of ACEE Advanced Curvature Mode ────────────────── 12-13
b) Constant Gauge Overlap Tolerance Factor ──────────────────── 12-15
c) Curve Offset Accuracy Factor ──────────────────────────── 12-16
Release Management Tab ────────────────────────────────── 12-17

Contents

1. Chapter 1: Overview/List of Packages
1.1 Introduction
Fibersim is a suite of CAD-integrated software tools designed to reduce the costs associated with the
design and manufacture of composite parts. Fibersim products work together with CAD systems to allow
a single 3D model of a composite part to be used from conceptual design through fabrication.
All composite part information is centralized because it can be stored, manipulated and revised within
one CAD model. Fibersim also simulates the behavior of composite materials, taking into account the
draping characteristics of a given material when determining whether a ply is producible.
By offering simulation techniques that are based on the way composite material actually forms on a
given 3D surface, you can more accurately design composite parts within the CAD system, before any
information is transferred to manufacturing.
As part of a special repackaging project, Fibersim has been divided into a 3-

tiered product. The terms CEE and ACEE are no longer used in relation to the
Fibersim product.
The product consists of three different packages:
• Base - This level allows ply-based modeling only. Users with the Base license will be able to develop
ply-based composite models and open any part that is simplified to Base-level objects.
• Pro - (roughly equal to the former “CEE”) - This level allows you to perform layer and ply-based
composite modeling. You can work with parts with layers, overlay zones, and ply data. You will be
able to open parts with zone data but unable to edit/change any zone objects. Only overlay zones
can be created and edited using a Pro-level license.
Note:
Current CEE licenses will be transitioned to Pro.
• Elite - (roughly equal to the former “ACEE”) - This level allows access to all of the supported
composite modeling methodologies within Fibersim. You can open and work with models with all
zone, layer, overlay zone, and ply data. The Elite level also supports Volume Fill and Wind blade
design.
Fibersim User Guide 1-1

Introduction
Note:
Current ACEE licenses will be transitioned to Elite.
Fibersim also contains a suite of optional products, that enhance its capabilities, such as Flat Pattern
Export, Laser Projection and Fiber Placement Interface. These products work in conjunction with
Fibersim to ensure a seamless link from the 3D CAD model to the manufacturing floor.
Because all information required for analysis and manufacturing is generated from a single CAD master
model, Fibersim ensures that all downstream processes will be driven by data that is complete and up-
to-date.
1-2 Fibersim User Guide

List of Fibersim packages
1.2 List of Fibersim packages
The main interface will consist of a certain methodology, depending on the package currently licensed:
PACKAGE INCLUDED SECTIONS IN THIS GUIDE
Base Allows ply-based modeling only.
• Chapters 2 (Base objects) and 7 (documentation) include the objects in

the Base package.
Pro Once composite part data is defined, you can generate producibility, flat
pattern, laser projection, automated cutting, and fiber placement data for the
entire part.
• Chapters 2 (Base objects) and 3 (advanced) are included objects in the

Pro package.
• Chapters 6 (ADD), 7 (documentation) and 8 (PSO) are also included

objects in the standard Pro package.
Elite This package exploits the inherent advantages of many different composite
design methodologies—including zone-based and ply-based design.
• Every chapter of this guide discusses elements included in a standard

Elite package.

About the Bundle values
1.3 About the Bundle values
This environment variable must be properly set to reference the package/bundle you are licensed for:
FIBERSIM_LICENSE_BUNDLE
This is set using the SES Licensing Options from the main installer, or it can be set manually.
Full details for the bundle values are discussed in Chapter 1 of the Installation Guide.

User Guide Breakdown
1.4 User Guide Breakdown
This is how this user guide breaks down.
SECTION DESCRIPTION CHAPTER
(on application
browser)
Basic Descriptions of all interfaces under the 2

“basic” section of the application browser.
Advanced Descriptions of all interfaces under the 3

“advanced” section of the application
browser.
Wind Blade Uses ply-based design for the production of 4

wind blades.
ADD Provides design tools that aid those who use 5

automated deposition machines, including
Fiber Placement and Tape Laying machines.
NOTE: ADD tools work with the Pro & Elite

packages.
Documentation Special documentation that helps you to 6

better understand your composite parts.
NOTE: Special license required for 2D

documentation.
PSO The PSO section on the application browser 7

contains objects which will be populated
with data once the PSO utility is run.
Import/Export For importing/exporting composite part data 8

Interfaces to analysts or manufacturing personnel.

User Guide Breakdown
SPECIAL NOTE: Each of these interfaces is

sold and licensed individually.
Machine & All Fibersim data is communicated using Index A

Materials Database XML technology. XML defines the Materials
Database and the Machine Database.
Utilities Utilities available for all aspects of Fibersim. Index B
Options Tools > Options > Fibersim Options Index C

About the Fibersim Icons
1.5 About the Fibersim Icons
This section discusses the icons you will notice as part of the Fibersim product.
ICON DESCRIPTION
Link with Link Dialog Button
Opens a window containing a list of objects you can select

from. These can be plies, rosettes, laminates, etc.
Link to Database
Opens a link to one of the Fibersim databases.
Geometry Link
Allows you to select and link to some element of the model,

within the CAD system
Save
For saving report or display results to a file.
Print
For printing reports or display results.

How Units Display in Fibersim
1.6 How Units Display in Fibersim
Fibersim uses the CAD system’s base unit settings for Length, Mass, Force, Time, Angle, and
Temperature, and then derives other units from the base units. Fibersim handles both the English
(Imperial) unit system and the Metric (SI) unit system. It will also handle several different settings for
each unit type.
Note:
When CAD display units change, Fibersim updates with the

new units.
This table illustrates supported units and the abbreviations for each CAD system. If the CAD system does
not allow setting of certain unit types, Fibersim displays CAD system defaults.
1.6.1 Supported Units and Abbreviations
Fibersim displays unit abbreviations in the interface.
Unit Type Unit Name & Abbreviation Creo CATIA V5 NX
Length
Millimeter (mm) Yes Yes Yes
Meter (m) Yes Yes Yes
Centimeter (cm) Yes Yes Yes
Kilometer (km) Yes Yes No
Micrometer (micron) Yes Yes No
Inch (in) Yes Yes Yes
Foot (ft) Yes Yes Yes

Supported Units and Abbreviations
Mass
Milligram (mg) Yes Yes No
Gram (g) Yes Yes Yes
Kilogram (kg) Yes Yes Yes
Metric Ton (MT) Yes Yes No
Ounce (oz) Yes Yes No
Slug (slug) Yes Yes No
Force
Newton (N) Yes Yes No
Pound Force (lbf) Yes Yes Yes
Unit Type Unit Name & Abbreviation Creo CATIA V5 NX
Time
Millisecond (ms) No Yes No
Second (s) Yes Yes No
Minute (min) No Yes No
Hour (h) No Yes No
Temperature
Celsius (C) Yes Yes No
Fahrenheit (F) Yes Yes No
Kelvin (K) No Yes No

How each CAD System Handles Units
1.6.2 How each CAD System Handles Units
Each CAD system that supports Fibersim handles units in a slightly different manner:
CATIA V5 You have control over all of the supported display units. However,
Fibersim uses the units only, and derives the other units from the base
units.
For example, CATIA V5 lets you specify display units for speed, volume,
pressure, and several other derived units.
Fibersim will not use user-selected settings for these units. It will derive
these units from the settings chosen for Length, Mass, Force, Time,
Temperature, and Angle.
NX NX only lets you select (lb-in), (lb-ft), (g-mm), (g-cm), (kg-m) for the
display units. Fibersim will use internal defaults for all other base display
units.
All other units will then be derived from the display units and the default
units.
Creo Creo Parametrics does not let you set a display unit that differs from
Parametrics model units. In Creo you are setting model units. Fibersim will display the
current settings for the model units.
Note:
If you select a Creo system that contains units not supported in
Creo, Fibersim uses internal defaults for these unrecognized units.
When you change unit systems in a part, Creo is actually changing the
model units, which converts all stored data in the part. You must
regenerate the flat patterns after model units have changed.

Fibersim Color Palette
1.7 Fibersim Color Palette
This table lists default color names and Red (R), Green (G), and Blue (B) values for the Fibersim-
expanded color palette.
Note:
Depending on the CAD system being used, the CAD system will take the
RGB values and approximate the color to use, as closely as possible.
# Color Name RGB Values
1 black 0,0,0
2 white 255,255,255
3 sandy yellow 255,190,71
4 golden yellow 250,190,71
5 orange salmon 242,162,87
6 pink salmon 234,132,102
7 light lavender 196,179,209
8 dark lavender 153,147,191
9 slate blue 131,170,214
10 sky blue 129,192,232
11 sea green 148,201,191
12 light sea green 174,209,155
13 light khaki green 191,205,144
14 dark gray green 126,162,151

15 gray 193,196,192
16 brown 211,178,125
17 salmon 255,128,128
18 pale yellow 255,255,128
19 pale green 128,255,128
20 spring green 0,255,128
21 cyan 128,255,255
22 dodger blue 0,128,255
23 pink 255,128,192
24 orchid 255,128,255
25 red 255,0,0
26 yellow 255,255,0
27 chartreuse 128,255,0
28 blue green 0,255,64
29 royal blue 0,128,192
30 dark slate blue 128,128,192
31 magenta 255,0,255
32 maroon 128,64,64
33 pink orange 255,128,64
34 green 0,255,0
35 teal 0,128,128
36 blue gray 51,51,102
37 pale blue 128,128,255
38 plum 128,0,64

39 light purple 255,0,128
40 burgundy 128,0,0
41 orange 255,128,0
42 dark green 0,128,0
43 aquamarine 0,128,64
44 blue 0,0,255
45 dark blue 0,0,160
46 purple 128,0,128
47 violet 128,0,255
48 olive 94, 120, 32
49 dark red 160, 36, 33
50 light grey 190,190,190
51 light slate blue 150,100,255
52 mauve 200,150,255
53 dark grey 128,128,128
54 safety orange 255,150,0
55 light orange 255,200,100
56 light pink 255,150,200


2. Chapter 2: Basic (Functions and
Interfaces)
2.1 Introduction
Engineers define composite parts by creating objects such as laminates, rosettes, plies and cores. During
definition, engineers associate these objects to their corresponding CAD geometry. All composite part
data is stored inside the CAD model, so that anyone possessing Fibersim, the CAD master model, and
the CAD system can access the composite part data. Composite part data can also be exported in an
XML format, which can then be transformed easily into web pages, office applications, and other
downstream systems.
After part definition has begun, engineers can use various Fibersim tools to verify that design
requirements are being met. Ply listing, sorting, and visualization tools let engineers inspect all aspects
of the layup, including material types, stackup order and orientations.

Basic (Application Browser)
2.2 Basic (Application Browser)
These objects are created in Fibersim, associated to relevant CAD geometry, and stored within the 3D
CAD model.
APP. DESCRIPTION SECTION

BROWSER
Laminate Organizational tool, that defines layup surfaces. 2.3
Rosette References for determining fiber orientations and defining 2.4

ply orientations.
Ply A single piece of material laid on the tool surface. 2.5
Together, plies and cores represent actual materials used to

fabricate a composite part.
Core(s) Similar to plies, cores represent components of a composite 2.6

layup.
Design Station Verification tool (for checking laminate properties) 2.7
Cutout Cutouts are holes in the part, that are generally machined 2.8
after a part has cured.

Basic (Application Browser)
Darts There are two types of dart techniques: one produces a slit 2.9
dart and another that produces a “V”-shaped dart.

Laminates
2.3 Laminates
A laminate is an organizational tool for grouping together plies, cores, and other laminates. It is also
used to define the layup surface and overall part boundary. Laminates contain various pieces of
information such as sequence, step, and part numbers.
Simply stated, a laminate is an assembly of composite objects. Just as any mechanical assembly can
contain several subassemblies, a Fibersim laminate may contain several sub-laminates, also known as
child laminates. This grouping creates the parent/child relationship.
Plies and cores are created as “children” of a parent laminate. When a laminate is defined, its
characteristics, such as layup surface and boundary, are shared by all child components.
Simple parts may be defined accurately using only a top-level laminate. Other parts, incorporating cores
or inserts, may require child Laminates to represent the significant change in layup surface, caused by
the addition of core. Complex parts containing Ply packs and/or subassemblies may require several
laminates to be accurately represented.
AT A MINIMUM: Laminates must be defined using a 3D layup surface and 3D boundary, representing
the overall shape of the finished part. Sequence and step values specify each laminate’s order in the
composite part stackup.

When to Define Additional Laminates
2.3.1 When to Define Additional Laminates
For every composite part designed, at least one laminate must be fully defined. A fully defined laminate
is one that has a surface and boundary associated to it, and has been assigned sequence and step values
giving it the right order in the composite part stackup.
Because the laminate serves two major purposes (surface definition and component grouping), there
are two major reasons for defining additional laminates in a composite design:
A.) To Represent changes in Surface Topology
When the layup surface topology of the composite part stackup changes significantly (due to ply or core
insertion), a new surface must be defined, so Fibersim can generate accurate flat patterns and laser
projection data.
A new laminate is created as a child of the top-level laminate. The new layup surface is associated to this
laminate, and plies laid on this new surface are created as children of this laminate.
B.) To Represent logical groups of Components (i.e. Subassemblies or Ply Packs)
Child laminates represent subassemblies that are manufactured offline, or simply to organize logical
groups of components. If no surface or boundary is defined for a child laminate, the surface and
boundary of the parent laminate are inherited automatically.
Child laminates can aid in ply definition. For instance, if several smaller plies of varying shapes are to be
laid in a particular area, it may be useful to assign these plies to a child laminate, whose boundary
represents overall shape of this smaller area. Since each ply inherits the outer boundary of its parent
laminate, this greatly reduces the time and effort required to define plies.

Laminate (interface)
2.3.2 Laminate (interface)
This section shows the members used in a laminate object.
MEMBER DESCRIPTION
Parent Reference to parent object. Laminates share the layup

surface and boundary of their parent laminate unless a
specific boundary is defined.
Design See section a) later.

Boundary

Net The laminate net boundary (or “engineering” boundary)

defines the final trimmed shape of the composite part.
Curves that define the boundary must exist on the surface.
Note:
The net boundary need not consist of a single closed
curve, only curves that form a closed loop.
Extended The manufacturing part boundary. Curves must exist on the

laminate surface.
Note:
Extended boundaries need not consist of a single
closed curve, only curves that form a closed loop.
GEOMETRY
Layup Surface Defines the surface associated to the laminate.

Requirements for a surface to be used as a Layup Surface
include:
• It must be continuous within the defined laminate

boundary.
• It cannot have any discontinuities or holes in the

region where the simulation will be run.
• If sections of the surface have holes as part of a post

machining of the part, or as part of the base layup,
these holes must be filled in before running the
simulation.
Note:
The surface normal must point in the direction of
layup. (This is crucial for creation of laser projection
data.) If defined with an incorrect normal, you should
flip the surface normal and re-run any Fibersim-
generated data.
SEQUENCING
Sequence The laminate’s sequence in the composite part stackup.
Step The laminate’s step number within the parent’s sequence.

The step must be given a real number value.

Sequence A laminate will contain ascending or descending Sequence/

Order Step values. As objects move away from the tool surface,
they will be in either descending or ascending order.
MATERIAL
Default The default material (from the material database), for

Material children of this laminate. This is automatically linked to a ply
when a new ply is created. When creating many plies, using
the same material for each saves time.
Zone-Based See section b) later.

Options

a) Design-to-Extended Design Approach (Design Boundary)
2.3.3 a) Design-to-Extended Design Approach (Design Boundary)
Normal Fibersim behavior means you have one boundary that is totally user-controlled (design
boundary) and one that is extrapolated from that boundary (derived boundary).
Traditionally, the Net boundary is the design boundary and the Extended boundary is one that is
derived. This design approach is ideal for situations where the manufacturing boundary is simply an
offset of the design boundary. The manufacturing boundary for each component can simply be derived
by extending each boundary to the laminate's extended/manufacturing boundary.
However, there are cases where the laminate's net and extended boundaries have completely different
shapes. In such scenarios, the correct extended boundary for each component cannot be derived by
extending its net boundary to the laminate's extended boundary. This is where the "Design-to-Extended"
design approach can be used to achieve the correct design. It allows you to define your components to
the extended boundary, and the net boundary will be derived by trimming each component back to the
laminate's net boundary.
The "Design-to-Extended" design approach is activated by setting the Design Boundary member to
"Extended". Note that it will always be set to "Net" by default.
SPECIAL NOTE #1: Once an option is selected, and OK is pressed on the

laminate, the Design Boundary option becomes read-only, and cannot be
changed.
SPECIAL NOTE #2: When set to “Net”, Fibersim functions exactly as it always
has.

a) Design-to-Extended Design Approach (Design Boundary)
Notes on a laminate set with the “Extended” option:
• Both a net and extended boundary is required.
• For all laminates created as children of a laminate with Design Boundary set to “extended”, the
children will also be set as design-to-extended.
• Any component that would previously have been defined to the laminate Net boundary, must now
be defined to the laminate Extended boundary. This includes plies, zones, layers, splice curves,
darts, etc.
• Holes must be inside the laminate's Net boundary.
Notes on plies (when the ply is linked to a parent laminate set to "extended"):
• The ply's net geometry members will be read-only.
• The ply's net boundary will not highlight, and net flat patterns cannot be generated.
• You cannot run net producibility on the ply.
Notes on layers:
• Net Geometry fields will become read-only.
• Result boundary features can only be generated for extended boundaries.
SPECIAL NOTE: Analysis data can still be produced for both net and extended
boundaries.

b) List of Zone-Based Options
2.3.4 b) List of Zone-Based Options
This is a list of zone-based options.
MEMBER DESCRIPTION
Default Stagger The type of stagger profile to apply to the laminate. This sets the
Profile stagger profile object link, on all zone transitions, to read only.
Lock Global Drop- Ensures that Fibersim prevents changing of the layer’s drop-off
Off Order order. The order will be changed dynamically by Fibersim.
Minimum Weight Nests largest layer shapes of this laminate inside smallest layer
Nesting shapes.
Drop-Off Order Number by which the drop-off values will increment.

Increment
Clear All Stagger Clears all the profiles.

Profiles
Layer Shape Defines internal pre-sorting of layers, before Zone Transition index
Nesting curves are applied to layers. Pre-sorting is based on:
• Zone Count - when using Linear Ascending or Linear

Descending drop-off pattern

b) List of Zone-Based Options
• Zone Area – when using Linear Ascending or Linear

Descending drop-off pattern
• No-Pre-Sorting
Note:
If you assign Zone Transition index curves based solely on
Drop-Off order, then it is recommended using No Pre-Sorting.
Sequence Based See the section below.

Projection
b1) Sequence-Based Projection details
When designing composite parts that contain cores, these parts provide unique challenges that are not
encountered on solid laminate parts. In addition to the OML surface, cored parts often require an
undercore, overcore, and IML surface to be generated.
• The undercore is developed to aid in the creation of the core solid.
• The overcore is used to develop ply shapes and flat patterns for plies placed over the core.
• The IML is created to complete the composite part solid.
Often, in the up front design, you do not know which plies will live on the OML, or which plies will live
on the overcore surface. You simply obtain gage data from stress, and need to define the part based on
this data.
You can input all zone data on the OML, and then check this option to project the necessary plies to the
overcore surface. This allows you to input the data as received from stress, and make changes received
from stress on the same set of zones.
To properly auto-project ply boundaries, you must create a second laminate that contains the overcore
surface and is parented to the top-level laminate. Then the laminates and plies need to be sequenced in
the correct layup order.

Analysis (for both Net and Extended boundaries)
2.3.5 Analysis (for both Net and Extended boundaries)
Laminate analysis calculates the center of gravity, weight, area, perimeter, and cost for entered plies.
There are two sets of analysis data for each laminate, one for the Net boundary and one for the
Extended boundary.
To properly update analysis data, Net producibility and Extended producibility (as well as flat patterns)
must be up to date.
NOTE: If the part contains cores, analysis data must be entered in the core form,
to be properly reflected in engineering and manufacturing analysis data.
Fibersim does not automatically generate core analysis information, it is
manually entered.
Net Analysis data is calculated based on Net boundaries.

MEMBER DESCRIPTION
Preliminary Fibersim lets you compute approximate net analysis data

Analysis Data (i.e. area, weight, cost) without first running a draping
simulation.
The draping simulation provides analysis data taking into

account deformations induced by draping. However, early
on in the design process exact data is not required (i.e.
approximate analysis data is good enough for initial
weight studies and cost estimation.)
When Update is pressed, Fibersim rolls up the analysis data

of the laminate's children. If approximate analysis data is
used for one or more of the plies then this option will be
checked.
NET
Analysis Status Specifies whether the laminate’s net analysis is up-to-date

or out-of-date.
Zone-Based Preliminary weight estimate of the composite part, based

Weight on zone boundaries.
Assert into NX This option asserts the net analysis (with cutout values) of
weight, center of gravity and moments of inertia in the NX
part, using advanced weight management.
CUTOUT
IGNORED
Center of Gravity Center of gravity of the laminate, given in X, Y and Z

coordinates. This is an area-weighted average of all
centers of gravity of the plies and cores that compose the
laminate.
Calculation is based upon the Net boundary. If flat

patterns are generated for extended boundaries of the
constituent plies, but not for net boundaries, no center of
gravity values are calculated.

NOTE: Net flat patterns must be run before Fibersim can

calculate the center of gravity.
Area Total area of all plies and cores in the laminate.
Weight Total material weight of all plies and cores in the laminate.
Cost Total cost of the material used.
Perimeter Summary of perimeters for all plies and cores, on the flat
pattern.
Moment of The moment of inertia (MOI) is important for designing

Inertia automotive parts. Fibersim will calculate, at the laminate
level, the inertia tensor (moment of inertia about the
arbitrary axis) for a composite part.
CUTOUT INCLUDED
Center of Gravity Displays the engineering, or net, center of gravity

coordinates.
Area Net/Engineering area of the flat pattern.
Weight Net/Engineering weight of the flat pattern.
Cost Net/Engineering material cost of the flat pattern.
Perimeter Net/Engineering perimeter of the flat pattern.

EXTENDED
This data is calculated based on the extended boundaries, also known as the
manufacturing boundary.
Analysis Status The status for the analysis, either up-to-date or out-of-
date.
Area Extended/manufacturing area of the flat pattern.
Weight Extended/manufacturing weight of the flat pattern.
Cost Extended/manufacturing material cost for the flat pattern.

Perimeter Extended/manufacturing perimeter of the flat pattern.


Laminate Object Toolbar (with utilities)
2.3.6 Laminate Object Toolbar (with utilities)
Note:
For details on these utilities, see Index B.
The laminate object toolbar:
MEMBER DESCRIPTION
Material Substitution Allows you to substitute materials used for zone

based design.
Symmetric Laminate Creates a duplicate dataset of a laminate, by

mirroring information about a symmetry plane.
Merge Models Merge together matching zone-based layers on

adjacent segments of a part that has been split up to
allow for concurrent design.
Surface Transfer
Manufacturing Lets you create a manufacturing dataset (a “child”

Laminate Creation dataset) from an engineering dataset (the “parent”
dataset). The “parent” is then linked to the “child”.
2D Laminate Creation Allows you to create a 2D representation of the 3D

laminate, by flattening 3D laminate data to a 2D
laminate.
Zone to Layer Automatically creates layers and plies from zone

Analysis definitions.
Explode Laminate Creates a visual representation of the ply stack-up, on

a selected laminate. This tool explodes each ply, at a
specified distance from each other

Laminate Object Toolbar (with utilities)
Step Utility Applies Step values based on layer areas.
Drop-Off Order Utility This utility assigns drop-off order values to layers for a
given material.
Mirror Laminate Creates “mirrored”, or copied, plies based on a set of

existing plies.

Rosettes
2.4 Rosettes
When a composite part is designed, a rosette is typically referenced on the part drawing. This rosette
defines the fiber orientations for the part and all plies composing the part. When a single rosette is
defined, fiber orientations elsewhere in the part are calculated based on that rosette. During ply
definition, you can simply enter a numeric value for ply orientation and the actual 3D orientation of the
ply will be calculated based on the rosette. Rosettes generally consist of four reference arrows
emanating from a point, with each arrow representing one of the 0°, 45°, 90°, or -45° directions.
A rosette is often referenced only for a single 2D view of the part. For flat or simply shaped parts,
transferring the rosette direction to a given location on the part can be straightforward; however, for
even mildly complex surfaces, interpreting the rosette direction on the part can be very difficult or even
ambiguous. This ambiguity can cause a composite part to be manufactured without the intended fiber
orientations of the stress analyst.
Fibersim rosettes are very similar to a conventional rosette referenced in part drawings. The major
difference is that Fibersim rosettes are defined in 3D space on the part surface, and can be used as a
meaningful orientation reference at any point on that surface.
Because it is defined in 3D, Fibersim rosettes have advantages. The orientation reference can be
automatically transferred anywhere on the part, accurately accounting for part curvature. You can also
enter numeric values when defining ply orientation, from 0° – 360°. When modifications are made to
the rosette, the orientations of all plies referencing the rosette are updated automatically, so that
subsequent producibility analyses reflect the change.
After the producibility simulation has been run, Fibersim’s Design Station utility can report true fiber
orientations at any point on the part surface, by measuring fiber orientations at that point against a
reference rosette.

Rosette Requirements
2.4.1 Rosette Requirements
At a minimum, rosettes are defined using a laminate surface, an origin point on the surface, 0°
direction, defined by a curve emanating from the origin point and a curve representing the part’s zero
degree direction at that point.
Besides the 0 direction, all other directions are automatically calculated by rotating the 0° direction
about the laminate surface normal, at the rosette origin, using the right-hand rule to determine
positive orientations.
Rosette Orientations (based on the right-hand rule)

Rosette Mapping Types
2.4.2 Rosette Mapping Types
When a rosette orientation is transformed to a different ply origin, the resultant direction of the ply will
depend greatly on how the rosette’s directions are mapped. Fibersim takes into account curvature of the
layup surface and the rosette mapping technique.
In general, a given part will use only one type of rosette mapping technique, regardless of the number
of rosettes placed on the part. The selection of the correct mapping technique depends on the output
desired and the curvature of the part.
However, there are particular guidelines for determining the recommended technique based on the
curvature of the part, and in most cases these guidelines will determine what mapping is selected.
Fibersim uses these rosette mapping techniques: Standard, Translational, Radial and Spine-Based.

Standard Mapping
2.4.2.1 Standard Mapping
With standard mapping, orientation is mapped from the rosette in a way that conforms to part
curvature. This correlates to how the fibers of a composite material conform to a surface. Fibers begin at
the specified orientation only at the ply origin, then conform to the curvature of the part.
In this image, the different sides of the cube can be viewed as drastic changes in curvature, as the
rosette is mapped to different areas of the cube. Surface normals point outward in all directions. Since
the Standard rosette always takes the surface normals at the new map point into account, the
orientation mapping will always be what is intuitively correct.
Notice that there is no arrow on the surface that is opposite the surface in which the rosette is defined
on. Standard rosettes map by intersecting two planes, one at the rosette origin and one at the ply origin.
In this case, the two surfaces are parallel so there is no line of intersection for the planes.
Fibersim will transpose the rosette directions exactly as defined on the rosette surface to the parallel
surface. If not the desired behavior, you should define a new rosette on the parallel surface.

Translational Mapping
2.4.2.2 Translational Mapping
Translation type mapping is considered a direct translation mapping technique.
Surface normals of the laminate surface are ignored and Fibersim conducts an exact point-to-point
translation when mapping the rosette. The 0° direction is mapped directly, and other fiber orientations
are calculated by rotating the translated 0° direction around the normal at the ply origin (not at the
normal of the rosette). The most common cases where a point-to-point translation mapping is desired is
in perfect surfaces of revolution where you want the 0° direction to always be parallel to an axis:
Translational Rosette Mapping
Note that Translational mapping does not apply to the majority of parts. Note the cube example again,
now using directional translation mapping. Note that the point-to-point translation fails on two out of
the six faces.
How NOT to Use Translational Mapping

Translational Mapping
The best rosette mapping for a part is a standard mapping that uses surface normals. Direct translations
are only desired on a small subset of parts, such as surfaces of revolution, as shown above.

Radial Mapping
2.4.2.3 Radial Mapping
Radial Rosette mapping is a specialized form of translation, for spherical-shaped parts.
In this type of mapping, the point-to-point transformation takes place but the 0° direction is always set
in the direction of translation, or radial from the center of the part. When the mapping takes place, the
direction of the 0° orientation is thus always pointing outward in a radial direction.
0 degrees, 45 degrees, 90 degrees & -45 degrees

Spine-Based Mapping
2.4.2.4 Spine-Based Mapping
This is for spine-based parts which provides a better orientation mapping, for parts like stringers and
spars. It defines the fiber orientation along a spine, used for part definition. The selected spine curve
must have a direction (which can be reversed).
Note:
Similar to the translational rosette, the spine-based rosette must lie on a

laminate surface (though not necessarily the part surface).

Field-Based Rosettes (details)
2.4.2.5 Field-Based Rosettes (details)
This fiber field rosette type allows you to define a rosette as a fiber field. The fiber field is defined by the
0 degree orientations specified on each element in the CAE mesh. These points are included in the file
as the rosette's mapping over the entire surface of the part.
You create a field-based rosette by importing from an HDF5 or CP XML external file. This automatically
creates a central point and direction for those rosette members.
The origin, direction, and mapping type members become read-only. The "Mapping-type" will only
display one option (Field-Based) and it will not be user-selectable. Field data will be saved on the rosette
object as a point cloud. When Fibersim maps to a point, nearby data points are found and a result is
calculated based on these points.
Note:
CAE import/export interfaces are discussed in Chapter 9.
At this point, the field-based rosette functions in the same way as any other rosette, with the exception
of highlighting, which will show a vector field instead of the rosette data at just the origin.
Note the new "field" rosette mapping visualization. This will show the zero-direction mapping over the
rosette surface. For non-field rosettes, this will be based off of a visualization mesh. This visualization
mode allows users to see how the specified rosette maps over the surface.

How to Define a Rosette
2.4.3 How to Define a Rosette
How a rosette is defined will directly affect how the rosette maps fiber directions on a composite part.
Standard Rosettes
A standard rosette is used on the majority of composite parts. To create a standard rosette, you only
need a point and a curve on the tool surface. The point defines the origin of the rosette, and the curve
defines the zero direction of the rosette.
Geometry to define a Standard Rosette:
• an Origin Point (must be on the Direction curve)
• a Direction Curve
Both of these must be on the parent Tool Surface.
Create a laminate that is associated to the Tool Surface, and also a rosette that is associated to the Origin
Point and Direction Curve. The rosette must have the laminate that contains the Tool Surface as its
parent.
Once all data is associated, Fibersim will correctly map the zero direction of the Standard rosette to the
ply origins.

Translational Rosettes
Translational Rosettes are used on surfaces of revolution that must have the zero direction always
pointing down the axis of the part. Examples of such tool shapes are composite nose cones, and aircraft
engine nacelles. This method of defining a Translational Rosette will directly influence how the zero
direction is mapped around the composite part.
If you place the rosette origin point and direction curve directly on the conical surface, the zero direction
will not correctly map around the composite part. Plies that use the rosette origin as their origin will
have a correct zero direction, however if an alternate origin point is selected for a ply, the mapping will
not behave as desired.
Translational Rosette (Incorrectly defined)
Ply01 uses the rosette origin as the ply’s origin. In this case, no mapping needs to occur, so Ply01 will
have a correct zero direction. However, Ply02 requires the direction to be mapped from the Rosette
origin to the Ply’s origin. This creates an erroneous mapping, as seen above.
The zero direction for Ply02 is skewed in from where it should be mapped. This will cause the simulation
to run in this incorrectly mapped direction. Incorrect mapping can be avoided by defining a Translational
Rosette like this:

Translational Rosette (Correctly defined)
To correctly define a Translational Rosette for a conical part, an additional surface needs to be created
for the rosette definition. This surface needs to be a planar surface that passes through the cone’s axis.
The rosette’s origin and direction then need to be defined on this surface.
The direction curve needs to be collinear with the cone’s axis, to ensure that the zero direction for the
rosette is exactly down the axis of revolution for the conical shape. The rosette origin point then needs
to be on the rosette direction curve for a correct rosette definition. Once the rosette is defined, the zero
direction for all the plies defined on the conical surface will be mapped correctly.
Notice that the Ply02 zero direction is now mapped correctly, when compared to the incorrect mapping.
To correctly associate the geometric definition, the surface used for the rosette definition needs to be
associated to a Laminate, that will only be used to define the Translational Rosette.
Then the conical surface (Tool Surface) needs to be associated to a second Laminate, which will be the
highest-level Laminate in the composite hierarchy. The laminates created for the Translational Rosette
and for the Tool Surface should not be parented to each other. The Laminate created for the
Translational Rosette is only used for creating the Translational Rosette. The hierarchy should look like
this:

Translational Rosette Laminate Hierarchy
When defining Translational Rosette, you must select the rosette laminate as the parent, then associate
the direction curve and origin point (defined on the planar surface) to the Translational Rosette.
You then create Tool Surface laminates as necessary. After selecting the created Translational rosette in
each ply, the zero direction will be correctly mapped to the ply origin for the conical shape.

Radial Rosettes
Radial Rosettes should be used on surfaces of revolution that must have the zero direction pointing in a
radial direction on the part. Most parts that use a Radial Rosette are dish or bowl shaped, such as
composite satellite dishes and radomes. Often for these types of surfaces, designers need the zero
direction of the fabric to always point along the radial direction of the part. How the Radial Rosette is
defined will directly influence how the zero direction is mapped around the composite part.
Radial Rosettes are defined by placing the rosette origin point at the exact center of the dish shape. The
fiber direction curve also needs to start, or at least pass through, the center of the dish shape.
You need to create a laminate that is associated to the Tool Surface, and also needs a rosette that is
associated to the Origin Point and Direction Curve. The rosette must have the Laminate that contains the
Tool Surface as its parent. Once this data is correctly associated, Fibersim will correctly map the zero
direction of the Radial Rosette to the ply origins.

Rosette User Interface
2.4.4 Rosette User Interface
This section defines functions of each rosette member:
MEMBER DESCRIPTION
GEOMETRY
Surface Select a surface for the rosette.
Origin The origin point of the rosette. This point must exist on the
rosette’s laminate surface, and also lie on the direction curve.

Direction Defines the 0× direction of the rosette. The direction curve must
exist on the parent laminate surface, and terminate at the
rosette origin.
MAPPING TYPE
Defines the mapping type used to generate rosette orientations:
• Standard
• Translational
• Radial
• Spine-Based
Note:
When a rosette is Translational, it may be defined from
reference of the Y-direction (90 degree axis), instead of
always the X-direction (0 degree axis).
Set the Direction Angle.
If a different coordinate system is used not currently supported

by Fibersim, use a translational rosette with the Y-direction (or
rosette 90 degree axis) to align with the centerline of a part.
Direction Angle of the selected direction curve (in degrees).

Angle
NOTE: When a rosette is Translational, it may be defined from

reference of the Y-direction (90 degree axis), instead of always
the X-direction (0 degree axis).
If a different coordinate system is being used that is not currently

supported by Fibersim, use a translational rosette with the Y-
direction (or rosette 90 degree axis), to align with the centerline
of a part.
Hand Direction of increasing degree angle of the rosette. Used in

Direction conjunction with the surface normals at the rosette origin.

DISPLAY
Spoke Length of the rosette's spokes or vector directions.

Length
Start Defines the first Rosette spoke as -45× or 0× (see below):

Angle
• -45 – displays spoke orientations as -45×, 0×, 45×, and 90×
• 0 – displays spoke orientations as 0×, 45×, 90×, and 135×
Fibersim displays the 0× spoke with an arrow. By knowing the 0×

direction, you can interpret remaining spoke orientations.
Create Whether Fibersim will create CAD geometry for the rosette (Yes)
Rosette or not (No).
Geometry
Fibersim always creates the 0° spoke with an arrow, so you can

visually tell which spoke is the 0° direction, and interpret the
remaining spoke orientations.
DEVIATION
Warning Deviation display warning angle for the rosette.

Angle
Limit Deviation display limit angle for the rosette.

Angle

Plies
2.5 Plies
A ply represents a single piece of material in a composite part. A building block of a composite part, it
contains a great deal of information because it exists in 2D as well as 3D. Together, plies and cores
represent actual materials used to fabricate a composite part. At a minimum, plies are defined with the
following:
• a laminate surface
• material type
• orientation
• origin (layup start point)
• 3D boundary
Sequence and step values are used to specify each ply’s order in the laminate stackup.
Plies must first be fabricated (generally cut out) from a sheet of 2D material. This cut out is known as a
flat pattern. The pattern is then laid up on a 3D tool. Fibersim stores all 2D, 3D, and non-geometric
information describing a ply including boundaries, orientation, material type, stackup order, and flat
pattern.

About 3D Geometry (for ply definitions)
2.5.1 About 3D Geometry (for ply definitions)
Since plies exist in both 3D and 2D there is the potential for several pieces of CAD geometry to be
associated to a ply.
• In 3D, plies require an origin, direction, and a boundary. Plies may also have holes and markers
associated to them in 3D.
• In 2D, plies contain a flat pattern that represents the shape of the composite material that will be
cutout and used in the manufacturing process. Plies can also contain a 2D origin, direction,
markers, and holes.
Fibersim uses two different ply boundaries: the Net boundary is the as-designed part boundary, and the
Extended boundary defines excess trim necessary for manufacturing.
This integration of ply boundaries allows Fibersim to be used for both the design and manufacture of a
composite part. If an Extended boundary is defined for the parent Laminate, Fibersim can auto-extend
the ply’s net boundary to generate manufacturing trim for the ply.
Once the 3D ply definition has been defined and producibility/flat pattern simulations have run, the
result is a 2D flat pattern. To modify the shape of a flat pattern, you should modify the 3D ply definition.

Ply (interface)
2.5.2 Ply (interface)
This section shows the members used for ply objects.
2.5.2.1 The Ply Toolbar
This toolbar contains the controls for running simulations, as well as ply-related utilities.
MEMBER DESCRIPTION
Net Producibility Runs producibility simulations for the Net boundary.
Net Flat Pattern Generates the net flat pattern.
Extended Producibility Runs producibility simulations for the Extended boundary.
Extended Flat Pattern Generates the extended flat pattern.
Flat Pattern Layout See chapter 7 for details on this utility.
Detect Course Allows Fibersim to detect basic issues with the producibility
Challenges of machine-laid plies, (i.e. minimum across cut angle
problems for tape, and minimum course length problems for
fiber placement).
Splice Ply Lets you splice selected plies based on predefined

boundaries.
Ply Drop-Off Creates smooth transitions, along boundaries of pad-up of

plies.
Fiber Path Curve Lets you create curves after receiving producibility results.
Creation

The Ply Toolbar
Standard Tab
MEMBER DESCRIPTION
OVERVIEW
Parent Parent laminate of the ply.
Note:
Plies automatically inherit their layup surface and
boundary (unless one is specifically defined) from the
parent.
Material The material from which the ply is made (from the materials
database). The material will determine the ply’s drapability

The Ply Toolbar
characteristics, thickness, areal weight, and material bolt

width.
ORIENTATION
Rosette The rosette associated to the ply. By default, ply origin is

inherited from the rosette.
Specified Orientation The ply's orientation, based on the selected rosette. You can
enter both positive and negative integers. See the special note
below on for details on NCF materials.
SEQUENCING
Sequence Defines the ply’s sequence in the composite part stackup.
Step Defines the ply’s step number within the composite part
stackup. Must be a real number value.
ORIGIN GEOMETRY
Origin Where on the 3D surface the ply layup begins. By default, the
origin is inherited from the rosette, but you can select an
alternate point. Ply origins must reside within the ply’s net
boundary.
Note how the location of the origin can affect future flat
patterns.
Direction Major fiber direction for the ply's material.
BOUNDARY GEOMETRY
Net Boundary Defines the ply’s engineering boundary.
Net Holes Defines net (or “engineering”) holes for the component.
ADDITIONAL GEOMETRY
Markers 3D curves or points to be flattened, exported or projected to

the flat pattern.

The Ply Toolbar
Darts Dart object used to eliminate wrinkling without splicing the

ply.
Wrapped
You can define a ply that overlaps itself (i.e. a wrapped ply) with this option. However,
note that this is only available on plies that have a two-domain boundary.
Define a Start and End curve. You can also reverse direction of the wrapping direction.
See the note later for more details.
DETAILS
Part Number Part Number for this component.
Function Function performed by this component.
Material Specifications This field will be automatically applied to any existing or new
ply objects. This field will only be populated once a Zone To
Layer update is run.

Notes on Wrapped plies
2.5.2.2 Notes on Wrapped plies
Here we have an example of a two-domain defined ply (blue curves/hoops) on a simple tube shape:
• Green phantom drawn line - This is the defined start curve. It denotes the beginning of the
overlapping section.
• Red phantom drawn line - This is the defined end curve. It denotes the end of the overlapping
section.
• Green arrows - These denote the direction of the overlapping. This can be toggled in either
direction using the Reverse Direction button.

CAD Note (NX only): Periodic Faces
2.5.2.3 CAD Note (NX only): Periodic Faces
Fibersim has difficulty simulating on periodic faces that contain the parametric seam (where surface
parameterization resets from 1 to 0). One indication of this condition is a simulation error about invalid
topology:
If this condition is encountered, the surface can be split along the seam. To do this use the "Divide Face"
command and split the surface with a plane, surface or curve that lies on the seam.
The 0/1 location of the edge is the seam location. If the surface is an extruded sketch, it usually lies on
the X-axis of the sketch. If it is a revolved section, it is the sketch plane of the section. Once the surface
has been split, Fibersim should run as normal.

Simulation tab
2.5.2.4 Simulation tab
These options give you more control over how the producibility simulation is run.
MEMBER DESCRIPTION
Working Net or Extended

Boundary
Simulation Allows you to select the type of simulation to run on a ply-by-ply

Method basis:

Simulation tab
• Traditional
• Curvature Adaptive - used with NCF materials
• Spine (beta) *
* If you select "Spine (beta)" as the simulation type:
• Propagation Method will be set to "To Curve" and be read-only.
• Whatever is set as the Specified Orientation will determine what

is set for the Propagation Direction (e.g. setting a 45 degree
orientation would set the direction to "Bias(+WeaveAngle/2)").
This will also be set to read-only.
FIBER SPACING
Specify Cell Size Check this option to be able to enter a fixed fiber spacing distance
value (rather than a factor). This will be un-checked by default.
Cell Size Here you can specify an absolute cell size instead of a relative fiber
spacing factor in the producibility simulation.
Fiber Spacing Controls simulation cell size. Default of 1.0 is usually sufficient for an
Factor accurate simulation, and to generate an accurate flat pattern.
Smaller fiber spacing results in denser producibility results. But there

are times when it is necessary to decrease this value in order to
maintain accuracy.
PROPAGATION
Actual The actual or measured orientation (if different from the specified
Orientation orientation).
Propagation Producibility simulation propagation method.

Method
• Standard – simulation starts at Origin, works progressively
outward in a radial fashion (simulates hand layup process).
• To Curve – simulation places cells along the Fiber Direction

Curve. This simulates a layup operator or a Tape/Fiber Placement
machine manually steering fibers along a chosen path.
• About Curve – simulates a layup operator first smoothing the

material around the Fiber Direction curve, then works outward
until it reaches the ply boundary.

Simulation tab
The display images will update based on the selected simulation

options and ply material.
These images illustrate how the simulation will solve for producibility.
While this is a diagram of propagation and not related to the
geometry of the part, it helps users to better understand the impact
of the set options on simulation results.
“About Curve” When the Propagation Method is set to “About Curve”, you can
propagation constrain the simulation propagation along an arbitrary curve, not
just the fiber direction curve. (You can select these two curves
independently.) When producibility is run, the selected constraint
curve will be used to constrain the simulation propagation.
Fibersim will automatically upgrade existing parts that have a curve

set for the Direction member and the ply is using an "About Curve" or
"To Curve" propagation method. Also, plies that are using the spine-
based simulation will also be upgraded to use the Constraint Curve.
The data upgrade will link the Constraint Curve member to the same
curve that is linked to the Direction member. Fibersim will NOT clear
the curve linked to the Direction member since this could have other
undesired effects on the ply's orientation. Users can manually clear
the curve linked to the Direction member if they desire.
“To Curve” "To Curve: Geodesic" - Fibersim calculates the constraint curve from
propagation the specified orientation.
"To Curve: Curve" - a user-specified constraint curve is used.
OPTIONS
Simulation An alternate simulation surface, used to eliminate holes from the

Surface producibility simulation.
First Stage Simulation will run in this region first, prior to flattening the
Region remainder of the ply. Must consist of a set of closed curves.
Constant Offset Whether or not to offset the simulation/flat pattern from the tool.
Mode
• Unchecked – results generated on parent laminate’s surface.
• checked – producibility results generated at a constant offset

from the layup surface (as specified in Offset Thickness).

Simulation tab
Results Display How the ply’s simulation results are displayed.
See the section later.

How a Ply’s simulation results display
2.5.2.5 How a Ply’s simulation results display
• Deformation (default) – Fiber paths are colored, indicating the level of distortion the material will
undergo during layup. Blue areas will undergo little or no material distortion, yellow areas will
undergo some distortion, and red areas will undergo significant distortion, causing wrinkling.
• Deviation – Fiber paths throughout the ply are measured against a reference Rosette, and are
colored depending on whether they exceed allowable values for deviation as specified on the
rosette.
• Areas whose fiber orientation deviates from the ply’s specified orientation by less than the limit
value specified on the rosette will be white.
• Areas whose fiber orientation deviates from the specified orientation by more than the warning
value, will be yellow.
• Areas whose fiber orientation deviates from the specified orientation by more than the limit value
are red.
• Steering – calculates the radius of curvature of the fiber paths, and then the fiberpaths are
colored, depending on whether they are below the allowable values for radius of curvature.
Note:
Steering display uses values specified in the TowROCWarning and

TowROCLimit parameters (in the materials database).
• Minimum Course – displays any minimum course length problems that may occur for the given
ply shape. Use this option when you are running a simulation on a ply whose material is a tow
material or a tape material. (These types of materials are laid down by fiber placement and tape
laying machines.)
An ADD Machine must be linked to the ply’s parent laminate.
IMPORTANT NOTE: With this simulation type, Fibersim is not doing any sort of path
planning.

The display has been enhanced to show tape and tow course for the visual appearance
only.

Enhanced Support for NCF Materials
Fibersim supports the input of non-crimped fabric (NCF) material orientations. NCF materials can
contain two or more layers of fiber tows, stitched together. The challenge is to specify a single
orientation to represent this material.
You can enter a series of orientations, that represent the different layers of fibers stitched together in
the NCF material.
Enters the NCF orientations here, using a series of angles, separated by a / symbol. The specified
orientations can be positive or negative values:

Note:
To use an NCF material, you need to define the <MaterialForm> member in the
Materials Database as NCF:
<MaterialForm>NCF</MaterialForm>

Cores
2.6 Cores
Cores are used to represent components of a composite layup. Plies are used to represent pieces of
material that are laid onto the tool surface, and cores are used to represent other types of inserts
incorporated into the layup. At a minimum, cores are defined using a laminate surface and 3D
boundary. Sequence and step values are used to specify each core’s order in the laminate stackup.
When designing composite parts it is often necessary to include a piece of core or other insert in the
composite stackup. There are four types of cores:
• Virtual Step Core
• Virtual Core
• Virtual Variable Core
• Modeled Core

Virtual Step Cores
2.6.1 Virtual Step Cores
A Virtual Step Core is a core type for handling the most common core (a standard core with a step). This
type of core aids in the use of defining these types of cores within Fibersim.
MEMBER DESCRIPTION
OVERVIEW

Virtual Step Cores
Parent A core requires a parent laminate, with an associated

surface.
Material Specify the material from which the core is fabricated.
SEQUENCING
Sequence Core’s sequence in the composite part stackup.
Step The core’s Step number within the sequence. Must be real
number.
GEOMETRY
Origin The origin point for the core.
Ribbon Direction The ribbon direction of the core.
Defined using a curve on the 3D layup surface. The curve

must reside within the core’s boundary.
Boundary The core’s footprint on its parent’s layup surface.
Boundary curves must exist on the parent laminate’s layup

surface, and form a closed loop that lies completely inside
the laminate’s extended boundary.
Holes Holes that are cut out of the core.
Each hole must be a single closed curve, that exists on the

parent laminate’s layup surface.
DIMENSIONS
Thickness Core thickness from the base shape to the top of the core.
Used in Core samples, and laser projection calculations.
Bevel Angle Constant angle of the bevel of a parametric core top.
Step Height The core’s step height.
Solid The core solid, used to attain analysis properties.

Virtual Cores
2.6.2 Virtual Cores
Virtual Core objects define the boundary, or footprint, of the core on the 3D layup surface, as well as the
cross-sectional shape of the core, using numeric values for thickness, bevel angle, and blend radius.
Over-core surfaces must be modeled explicitly to generate accurate

producibility and Flat Pattern data.

Virtual Cores
MEMBER DESCRIPTION
OVERVIEW
Parent A core requires a parent laminate, with an associated surface.
Material Specifies material (from the database) from which the core is
fabricated.
SEQUENCING
Sequence Core’s sequence in the composite part stackup.
Step The core’s Step number within the sequence. Must be real number.
GEOMETRY
Ribbon Direction The ribbon direction of the core. Defined using a curve on the 3D
layup surface. The curve must reside within the core’s boundary.
Boundary The core’s footprint on its parent’s layup surface.
Boundary curves must exist on the parent laminate’s layup surface,

and form a closed loop that lies completely inside the laminate’s
extended boundary.
Holes Holes that are cut out of the core. Each hole must be a single closed
curve, that exists on the parent laminate’s layup surface.
TOP
Thickness Core thickness from the base shape to the top of the Core. Used in
Core samples, and laser projection calculations. See image below.
BOTTOM The core solid, used to attain analysis properties.
Thickness Thickness for the core from the base shape to the bottom of the core.

Virtual Cores
This thickness is used in core samples and laser projection

calculations.

Virtual Variable Cores
2.6.3 Virtual Variable Cores
Virtual Variable Core objects define the base core boundary and top of core boundary. You can vary the
bevel angle of the core on all sides. Sometimes core pieces butt together with a 90-degree edge, so
make base and top boundaries coincident where the core will butt to another core piece. (See images
below.)
Differences in geometric shape of the Base and Top Boundary will define the core bevel shape. In the
area where the inner (cyan) curve overlaps the outer (black) curve, the core will have a 90-degree edge.
This technique defines multiple pieces of virtual core that will butt together. By knowing the distance
between the two curves and the thickness of the core, the bevel angle can be approximated using
simple trigonometry. (See images below.)
There are several necessary variables to determine the bevel angle. You usually know the core thickness
(t) and the bevel angle (). In this case, the unknown variable is the distance (D) between the base
boundary and the top boundary. The distance (D) can be determined like this: D = t/tan()
In another scenario, users may have the distance (D) and a thickness (t), and the unknown is the angle
(), which is found like this: = tan-1 (t/D)
NOTE: Trigonometry here assumes a right angle triangle can be formed. On surfaces of
large curvature, assuming this may result in erroneous results.
You can generate core sample, surface offset, and laser projection data without the need for an
explicitly modeled over-core surface. Note that over-core surfaces must be modeled explicitly to
generate accurate producibility and Flat Pattern data.


MEMBER DESCRIPTION
OVERVIEW
Parent Cores require a parent laminate with an associated surface.

Note:
Both the Base and Top Boundary must be defined on the
surface of the parent laminate.
Material Specifies the material from which the core is fabricated.
SEQUENCING
Sequence Defines the core’s sequence in the composite part stackup.
Step Defines the core’s step number within the parent’s sequence. Must
be a real number value.
GEOMETRY - BASE
Ribbon Direction The ribbon direction of the Core. Defined using a curve on the 3D
layup surface. Curve must reside within the boundary.
Boundary Outer boundary of the core. Boundary curves must exist on the
parent laminate’s layup surface, and form a closed loop that lies
completely inside the laminate’s extended boundary.
Holes Inner hole boundaries for the core.
Solid The core solid, used to obtain analysis properties.
GEOMETRY - TOP
Thickness Core’s top thickness.
Boundary Top boundary of the core. Boundary curves must exist on the parent
laminate’s layup surface, and must form a closed loop that lies
completely inside the laminate’s extended boundary.
Holes Top hole boundary of the core. Top hole curves must exist on the
parent laminate’s layup surface, and must form a closed loop that lies
completely inside the core’s top boundary.
GEOMETRY - BOTTOM
Thickness Core’s bottom thickness.

Boundary Bottom boundary of the core. Core boundary curves must exist on
the parent laminate’s layup surface, and must form a closed loop that
lies completely inside the laminate’s extended boundary.
Holes Bottom hole boundary of the core. Top hole curves must exist on the
parent laminate’s layup surface, and form a closed loop that lies
completely inside the core’s top boundary.

Modeled Cores
2.6.4 Modeled Cores
In order to generate accurate Flat Pattern and producibility data, a “Modeled Core” object and over-core
laminate/tool surface must be used.
Modeled Core objects define only the boundary, or footprint, of the core, while an over-core laminate’s
layup surface defines the core’s 3D shape. Producibility analysis for all plies created as children of the
over-core laminate will be performed using this over-core layup surface, and core sample or laser
projection thickness will be determined by measuring the distance between the over-core surface and
the preceding laminate’s layup surface.
Using Modeled Cores requires creation of an over-core laminate, immediately following

the core in the composite part stackup.

Modeled Cores
MEMBER DESCRIPTION
OVERVIEW
Parent Cores require a parent laminate with an associated layup surface.
Material Specify the material from which the core is fabricated, from the
materials database.
SEQUENCING
Sequence Defines the core’s sequence in the composite part stackup.
Step Defines the core’s step number within the parent’s sequence. Must
be a real number value.
GEOMETRY
Ribbon Direction The ribbon direction of the core. This is defined using a curve on the
3D surface, that must reside within the core’s boundary.
Boundary Defines the core’s footprint on its parent’s layup surface.
Boundary curves must exist on the parent laminate’s layup surface,

and must form a closed loop that lies completely inside the parent
laminate’s extended boundary.
Holes Inner hole boundaries for the core. Each hole must be a single
closed curve that exists on the parent laminate’s layup surface,
inside the core boundary.
Solid The core solid, used to obtain analysis properties.
Specified Defines a thickness value for the core.

Thickness
Fibersim calculates the thickness based on the surface-to-surface

distance, and the defined ply stackup.

Design Stations
2.7 Design Stations
During the composite design process, it is often necessary to check various points throughout a
Laminate to determine if the design meets requirements, such as thickness, ply count, and orientation.
To this end, the design station object performs core samples on the laminate.
Design station objects are defined by specifying a point of interest (origin) on the laminate surface,
where Fibersim will perform core samples. During a core sample, Fibersim builds a list of all plies and
cores covering the design station origin. Results are stored on the design station object.
Fibersim offers several core sample types for obtaining laminate information:
• Summary core samples provide component list, specified orientation, and thickness data.
• Detailed core samples provide actual fiber orientation data at the design station origin, by
measuring results from the producibility simulation against a reference rosette.
• Laminate Rating core samples provide symmetry, balance, and warpage calculations based on the
specified orientation of each found ply.

Understanding Core Sampling
2.7.1 Understanding Core Sampling
The theory behind a core sample is that you should get the same results, regardless of the surface the
core sample is initiated on. Select a point in the general area and you should obtain the same results,
regardless of which surface the point originates.
Note:
There are special cases where this theory can be disproved.

How Core Sampling Works
When generating a core sample, Fibersim creates an infinite line based on the surface normal direction
at the point where the sample is defined. Fibersim can intersect all surfaces encountered along this line
and create corresponding results. This is an example of three flat plates, representing three different
tool surfaces:
Surface Intersections
As seen by the green lines, Fibersim uses the surface normal at the sample location and shoots out an
infinite line. Results for the core sample points defined on Surface 1, Surface 2, and Surface 3 would be
identical.

The image below is the same example, except plies have been added to further explain the results.
Surface Intersections (with plies)
There are three core sample locations defined; Point 1, 2, and 3. Core sample results for these points are
identical. The ordering of the laminates in the results is not dependent on whether the core sample is
taken at Point 1, 2, or 3. Results list the plies in parent hierarchical order:
• Surface 1 is the parent; so the plies are always listed first regardless of whether the sample is done
from Point 1, 2, or 3.
• Surface 2, is the first child in hierarchical order so plies for this surface are listed next.
• Surface 3 is the second child, so these plies are listed last.

This creates the following ply order:
SURFACE 1:
Ply2
Ply1
SURFACE 2:
Ply4
Ply3
SURFACE 3:
Ply6
Ply5
This is the order for each core sample defined at Point 1, 2, and 3. The order, based just on parent
hierarchy will always be the same, however, the order of plies on a given surface can vary based on user-
defined inputs.
These inputs include the surface normal direction and whether the laminate is defined as “ascending” or
“descending”.
There is one case that Fibersim will recognize that plies on a given laminate need to be inverted, to
ensure the core sample is listed in cross section order.

Ply Listing (for IML Tool Surfaces)
Fibersim always lists core sample results based on the laminate parent hierarchy, and then the Sequence
and Step that individual plies have been assigned on each laminate. In some cases, based on the normal
direction and the laminate order (“ascending” or “descending”), plies have to be inverted from the
sequence step order to ensure they are listed in cross sectional order.
For core samples that intersect more than two surfaces, many cases arise where inversion may be
necessary. Fibersim always displays the correct plies and ply information for a given core sample result.
However, due to the abundance of sequencing cases for multiple surfaces, ply order listings can be non-
intuitive. Fibersim will always process the correct cross section ordering for core samples that intersect
two surfaces, and the parent is defined as an ascending laminate.
This image illustrates a special case where Fibersim identifies that the plies must be inverted to ensure
the core sample results are listed in cross section order.
IML ToolSurface Case
Fibersim will invert the order of the child laminate for any core sample that has the parent and child
surface normal pointing toward each other, and the child laminate is defined as ascending.
The plies are ordered this way since the IML and OML surfaces are both representing tool surfaces. So, if
Fibersim listed the plies based on parent hierarchy and ply sequence step, the cross section order would
be incorrect. (Ply4 would be listed before Ply5, which is incorrect based on the cross section shown
above).

This example is illustrating two tool surfaces that are laid up separately and then assembled into one
laminate. This is a case that is used by many composite part manufacturers so it has been accounted for
during a core sample.
Note:
We continually assess customer needs for handling specific part

sequencing, so, additional cases will be added based on customer
demand.

Multiple Intersections on Same Surface
There are cases where you can obtain non-intuitive results, based on surface geometry and where a
point is selected. These cases are usually encountered when Fibersim intersects the same surface more
than once.
Fibersim does handle multiple intersections with the same surface, but drops the second intersection,
and any intersections encountered beyond it with the same surface.
With a shape that represents a wing surface or a fairing that wraps back in a u-shape, Fibersim will
intersect the surface more than once. Fibersim drops the second intersection, which prevents non-
intuitive core sample results.
For example, if full body plies were intersected twice, the calculated laminate thickness for the core
sample would be incorrect. Fibersim removes the second intersection, and any intersections
encountered beyond it. This image shows intersecting the same surface more than once, and
intersecting other surfaces defined in the model.

Specific Example of Multiple Surface Intersections
This is an example of an I-Beam cross section where Fibersim intersects multiple surfaces. A core sample
will display ply results at the Surface 1 intersection, and plies at the design station point on Surface 2.
The second intersection with Surface 2 and Surface 3 will be truncated. Since Fibersim can intersect
multiple surfaces during a single core sample, you may want to limit intersections, by defining a
maximum intersection distance.

Using “Max Intersection Distance”
Using default core sampling is not possible to obtain core sample results for specific surfaces, since
Fibersim intersects all surfaces found in the parent surface’s normal direction. But you can define a
design station with a maximum intersection distance.
This distance defines the maximum distance along the surface normal for core sampling. This allows you
to intersect only the surfaces necessary for desired core sample results.
In this example, you only want ply results for Surface 1 and Surface 2. This is possible by defining a
design station on Surface 1 or Surface 2 and setting the max intersection distance to 1 inch.
Fibersim then shoots out a 1 inch line, in both directions from the surface normal, at the point where
the design station is defined.

If no maximum intersection distance is specified, core sample results will give ply information for
Surface 1, Surface 2, and Surface 3.

Design Station Object
2.7.2 Design Station Object
To have the design station perform core samples on the laminate:
1. Specify a parent laminate and rosette.
2. Specify a point of interest (Origin) on the laminate surface. This is where Fibersim will perform the
sample. Fibersim will build a list of all plies and cores covering the design station origin.
3. Specify the type of sample you want to perform (Core Sample Type).
MEMBER DESCRIPTION

Laminate To performs a core sample, a parent laminate (with an associated layup

surface) is required.
Rosette When core samples are performed, this rosette measures actual fiber
orientations.
Origin Defines a point on the 3D surface where the design station origin is
located. Core samples are performed at this origin.
Boundary Core samples are propagated to the plies’ Net or Extended boundaries.
Type
Core Sample Defines the type of Core sample performed. See next section for full
Type details.
Target Target thickness for the design station, for comparison to the actual
Thickness thickness. If material specs are linked, this member updates based on
cumulative ply counts of the material specs.
Target Ply Target ply count for the design station, for comparison to the actual
Count count. If material specs are linked, this member updates based on
cumulative ply counts of all the material specs.
Max This distance defines the maximum distance along the surface normal,
Intersection for core sampling. The distance propagates in both the positive and
Distance negative surface normal direction, from the origin. By restricting which
surfaces are used when sampling the part, you can obtain results for
individual surfaces
NOTE: Surfaces beyond this limit are excluded from core sample results.
The distance is defined on Surface 1, and shoots out 1 inch on both sides
of the surface, in the surface’s normal direction. Since there are no
surfaces below Surface 1, only Surface 1 and 2 are intersected. You will
only obtain plies found on Surface 1 and Surface 2.


Types of Core Samples
2.7.3 Types of Core Samples
Fibersim provides three types of Core samples for obtaining various pieces of information about a
laminate, Summary, Detailed and Laminate Rating samples.
2.7.3.1 Summary samples
Summary core sample results include total thickness and ply counts, as well as a list of plies covering the
station origin. Material type, thickness, specified orientation, and sequence-step data is provided for
each ply. Summary samples are used frequently throughout the design process.
Note:
These samples do not provide actual fiber orientation data based on

producibility simulations. To assess actual fiber orientations of the as-
manufactured part, a Detailed Analysis must be performed.

Detailed samples
2.7.3.2 Detailed samples
Detailed samples provide true fiber orientations of the as-manufactured part (at the Design Station
origin.) This is valuable, since true fiber orientations in a ply may deviate significantly when plies
conform to complex curvature:
Specified Orientation vs. Actual Orientation
This image shows a 0° ply started at the nose of the part, to obtain quasi-isotropy with the 45° nose ply.
Due to compound curvature, fiber orientations of the 0° ply actually become 45° near the back of the
part. (Note that the smaller 45° ply defined at the back of the part will not be sufficient to achieve a
quasi-isotropic layup.)
The summary core sample will report the specified orientations of each of these three plies. For a
sample performed at the nose of the part, one 0° ply and one 45° ply will be reported, accurately
informing you that quasi-isotropy has been achieved. But at the rear of the part, the summary sample
reports one 0° ply and one 45° ply, indicating that the layup is quasi-isotropic.
Orientation of the 0° ply is actually at 45° near the rear. Despite specified orientations reporting a quasi-
isotropic layup, analysis of the actual fiber orientations near the rear reveal that the layup is not. To
assess isotropy accurately, a detailed sample must be used.

Detailed samples
This image shows a modification to the design based on a detailed core sample analysis. Since the 0/90°
ply is deforming to +/-45° towards the back of the part, the smaller +/-45° ply at the rear of the part was
changed from a +/-45° to a 0/90° orientation, thus achieving a quasi-isotropic layup.
Since detailed core samples rely on producibility simulations, all ply definitions must accurately reflect
the manner in which each ply is manufactured for detailed core sample results to be meaningful. If the
simulation parameters do not accurately reflect layup methods used during manufacture, core sample
results will be incorrect.

Laminate Rating Samples
2.7.3.3 Laminate Rating Samples
Laminate ratings for core samples provide information on the symmetry, weighted symmetry,
mechanical symmetry, balance, and warpage of the laminate.
The thickness and ply count reported is of pierced components included in the laminate rating, not
necessarily those of all pierced components.
Note:
Not all materials contribute to laminate symmetry (i.e., wire mesh, release plies,
adhesive film, etc.).
The material database column “Laminate Rating” determines if a material will be
evaluated in a Laminate Rating analysis (set to either Yes or No).

DESCRIPTION
Symmetry This is the percent of encountered components pairs equidistant from the
laminate centerline that have identical fiber orientations.
Fibersim checks the components that are the first above and first below
the centerline to see if they are the same orientation and material.
Fibersim proceeds with subsequent sets of components.
The symmetry is the number of symmetrical pairs divided by the total

number of pairs.
Weighted The weighted symmetry assigns weights to the symmetry, such that
Symmetry asymmetrical plies that are further from the centerline will decrease the
symmetry rating more than those closer to the centerline.
The first pair of plies uses a weight of 1 if there is a pivot ply (an odd
number of plies in the laminate rating) or 2 if there is no pivot ply. Each
subsequent set of plies increases the previous weight by 1. The sum of
the weighted symmetrical components is divided by the total weight
(sum of all the weights for the symmetric pairs) to get the weighted
symmetry.
Mechanical Mechanical symmetry looks at the mechanical properties of components

Symmetry that are equidistant from the centerline. Properties are only examined for
the primary fiber direction for symmetry contributes along the 0
direction. This means that 90 plies do not contribute to the calculated
mechanical symmetry.
Fibersim calculates the neutral axis for the stackup using the primary fiber
axis modulus and the primary fiber angle. The mechanical symmetry is
based on relating the neutral axis to the laminate thickness.
Since contributions from plies that are close to 90 from the 0 direction are
ignored, these mechanical symmetry results should be regarded with
caution for laminates with 90 plies.
Laminate Laminate balance looks at plies that are not aligned or orthogonal to the
Balance 0 direction, to see if there are the same number of plies with orthogonal
fiber orientations (i.e. if you have 4 plies with a +45 orientation and 3
with a -45 orientation, then one of the +45 plies is unbalanced.)
Laminate Laminate warpage uses a similar approach as mechanical symmetry.

Warpage
Only the primary direction properties are considered. The thermal
expansion coefficient is applied to the components using a change in

temperature of 250 F (or the equivalent for Celsius for a metric material).
As with mechanical symmetry, results should be regarded with caution
for laminates with 90 plies.

Cutouts
2.8 Cutouts
Cutouts are regions that are subtracted from the entire laminate for the purpose of calculating more
accurate weight, area and cost data
The cutout affects the entire parent laminate. Any intersection between the cutout area and ply area on
the parent laminate will be reflected in the ply Net analysis. (Net Analysis is calculated with and without
Cutout areas.) Cutouts are also included in the Net Analysis.
MEMBER DESCRIPTION
Laminate The parent laminate.
Origin Select or indicate an origin point (inside of the Cutout boundary).
Boundary The cutout boundary. Boundaries can be broken against the laminate
net boundary, or can be a set of curves that form a closed loop.

Cutouts
Cutout Within "picture frame" designs, you can apply individual cut-outs, and
Propagation propagate on a laminate-by-laminate basis (i.e. one to the parent
laminate only, and one to the child laminate only).
Purpose Select or type a specific purpose for the given cutout (i.e. window,
door weight, etc.)

Darting
2.9 Darting
Darting techniques attempt to eliminate wrinkling in a ply without dividing it into smaller pieces. As a
ply is draped over a layup surface, fibers that are placed on the tool surface have an effect on the
deformation of subsequent fibers in the ply.
When a wrinkle is encountered, it generally propagates outward in the direction of the layup even over
simple curvature in the layup surface. Darting attempts to cut the initial fibers that initiate the wrinkling,
and prevent the wrinkle from propagating through the ply.
There are two types of darting techniques, one that produces a slit dart and another that produces a “V”-
shaped dart. Slit darts are used for out-of-plane wrinkling while “V”-shaped darts are used for in-plane
wrinkling.

Interpreting Producibility
2.9.1 Interpreting Producibility
As the producibility simulation drapes material over a 3D surface, it may encounter a region on the
surface that requires the material to severely deform to maintain contact with the surface. If the
deformation exceeds the user-specified limit angle of the material, it is considered to be wrinkling, and
Fibersim displays all fiber paths in this region in the color red. There are two basic types of wrinkling that
can occur during the layup process:
• Puckering – This wrinkling is common in apparel (for example, it occurs behind the knee in a pair
of pants when the knee is bent). It is caused by an excess of material in a given region of the
surface. The material, having draped all available surfaces, deforms off the surface in a plane that
is normal to the surface. Referred to as “out-of-plane” deformation.
• Bridging – This is caused by a lack of material in a given region of the surface. The material is not
physically able to drape over the entire surface the material spans or bridges regions of the surface.
The material deforms in a plane that is parallel to the surface. This is often referred to as “in-plane”
deformation.
To determine the type of wrinkling occurring in the simulation, one must observe the direction the red
fiber cells are deforming relative to the ply origin. If red fiber cells are elongating along a line drawn
through the ply origin, the material is puckering. If red fiber cells are shortening along a line drawn
through the ply origin, the material is bridging.
Determining the type of wrinkling is important when darting ply boundaries. The type of wrinkling helps
determine if a slit or V-shaped dart should be used. Decisions made by the user, with Fibersim feedback,
to determine alternatives for splicing the ply. In general, slit darts are used to alleviate puckering and V-
shaped darts are used to alleviate bridging.

Slit Darts
2.9.2 Slit Darts
Slit darts are used to eliminate wrinkling in a ply, without splicing it. You can be creative in using darts
so desired results are achieved.
MEMBER DESCRIPTION
Laminate
Dart Feature Displays the name of the dart geometry associated to the dart
object.
Slit Curve Definition - Points
The dart will be created using Base Curve Points to define it.
Base Curve Points Points used to create the dart. Should be selected in order from the
top of the dart toward the trim curve or net boundary. The order in

Slit Darts to Eliminate Wrinkling (Puckering)
which the points are selected determines the order for creating the
dart.
Note:
Define Dart Using needs to be set to “Points”.
Slit Curve Definition - Curve
The dart will be created using a Base Curve to define it.
Base Curve The curve that Fibersim offsets (by the Offset Distance) to create
the complete dart feature. Once a slit curve is selected, an arrow
indicates the curve’s direction.
To properly generate the dart, the arrow must point from the top of
the dart toward the trim curve or net boundary. If pointing in the
wrong direction, the Reverse Curve member must be used.
Offset Distance Gap between the two legs of a slit dart. Minimum value is calculated
based on current model tolerances. If CAD defaults are used, default
is 0.030 inches or 0.762 mm.
NOTE: Creo, by default, uses floating model tolerances. If the

tolerances change by a significant amount the minimum dart offset
distance will change and darts need to be regenerated.
Trim Curves Curves that define the boundary at which the dart ends. If no trim
curve is specified, Fibersim trims or extends darts to the Net
boundary.
Reverse Curve Reverses the direction of a Slit Curve. An arrow indicates the curve’s
direction.
Slit Curve Orientation
The slit curve orientation is correct since the green orientation

arrow points from the top of the dart toward the bottom. For this
example, Reverse Curve should be set to No.
Generate Dart Generates the dart feature. If a dart is modified and this button is
Feature pressed, old dart geometry is overwritten.
2.9.2.1 Slit Darts to Eliminate Wrinkling (Puckering)

The first step in creating a valid slit dart to eliminate puckering is to determine which initial fibers must
be cut, to prevent subsequent wrinkling. These fibers are determined from producibility display (see
below).
First, the area of red or wrinkled fibers is identified. Next, curves are traced from the two edges of the
red fiber region back toward the Ply origin, along a fiberpath. (These curves do not have to be drawn in
CAD, but are done here for clarity; see dashed lines.) The location where these two curves intersect
indicates the location of the fibers that must be cut. Often, these fibers are not red fibers, and can be
some distance from the area of red or wrinkled fibers.
Determining Dart Location
The next step is to determine the path of the dart over the layup surface. The optimal path starts at the
initial fibers that must be cut, and passes through the center of the red wrinkled region, to the edge of
the Ply boundary. However, sometimes the optimal dart path may pass through regions of the part that
are designated as “no cut” zones. In these cases, the dart path must be modified from the optimum.
As a general rule, a valid dart path is any that cuts the initial red fibers and continues to the edge of the
ply boundary. This image shows the optimal dart path.

Optimal Slit Dart
The resulting slit dart has eliminated the red or wrinkled region of the ply. This ply is now producible and
a flat pattern can be generated.
Note:
There is more than one solution to a darting problem. Solutions become

the decision of the designer, based on design requirements.

Valid Slit Dart Geometry for Wrinkling (Puckering)
2.9.2.2 Valid Slit Dart Geometry for Wrinkling (Puckering)
All valid slit darts consist of three curves defining a “U-shaped” gap. A dart is composed of two curves on
the layup surface, which are at least 0.030 inches apart at every location, and a third curve to adjoin
them. The free ends of the two “side” curves must terminate or be incorporated into an existing ply
boundary. The image below shows a schematic of valid slit dart geometry.
Using Fibersim’s dart creation tool, the geometry shown below is created automatically. However, you
could replicate the geometry manually, and add the curves to the ply boundary.
Fibersim will automatically calculate the minimum dart width based on the current model tolerances.
The minimum default value is 0.030 inches or 0.762 mm, however this value may need to be increased
if the model tolerances change.

V-Shape Darts
2.9.3 V-Shape Darts
V-shaped darts are used when material is bridging over the surface. A bridging condition indicates that
there is not enough material in the region. V-shaped darts basically define two curves that meet at a
point.
MEMBER DESCRIPTION
Dart Feature Specifies the generated dart feature.
INPUTS
Define First Curve Points or Curve

Using

V-Shape Darts
Base Curve Points Points used to create the first dart curve. Points should be selected
in order from the top of the dart toward the trim curve or net
boundary. Order determines the order to create the dart.
Define First Curve Points or Curve

Using
Second Curve Points to create the second dart curve. The top of the first dart
Points curve is used as the top of this curve, to ensure that both curves
form a vertex at the top of the dart. Lead the second dart curve
from the top of the first dart curve to the trim curve or net
boundary.
OPTIONS
Trim Curves Curves defining the boundary at which the dart ends. If no curve is
specified, Fibersim trims or extends darts to the net boundary.
Regions
No Dart Regions Defined regions where there should not be any darts.
Toggle Region Turn on/off display of No Dart Regions.

Display

V-Shape Darts to Eliminate Wrinkling (Bridging)
2.9.3.1 V-Shape Darts to Eliminate Wrinkling (Bridging)
Although the same slit darting techniques described above for out-of-plane wrinkling can be used in a
region of in-plane wrinkling or bridging, they will produce an invalid flat pattern.
The nature of in-plane wrinkling causes a lack of material in a given region of the surface. Placing a slit
dart in a region of in-plane wrinkling allows more material to enter that region. When the 3D draped
material is unfolded into a 2D flat pattern, this extra material becomes an overlap. An example of a slit
dart placed in a region of in-plane wrinkling or bridging is shown below, and the resultant 2D flat
pattern with overlap is shown in the image on the right.
Slit Dart in Location of Bridging Pattern (w/Overlapped Material)
Results indicate that slit darting will not work in regions of in-plane wrinkling or bridging. To eliminate
in-plane wrinkling, two plies must be created: the original ply with a V-shaped dart and a patch ply to fill
in the V-shaped area. Boundaries of both can be determined using producibility display.
The first step is to place a valid slit dart, with the techniques for out-of-plane wrinkling, in the region of
in-plane wrinkling. Slit darting produces an invalid flat pattern that will overlap on itself. While
generating producibility information for this darted ply, Fibersim shows an overlap condition in the 2D
flat pattern, and adjusts producibility display accordingly.
The image below shows the producibility display in a slit darted region of in-plane wrinkling. Fibersim
does not display 3D fiber paths in any region on the surface where the 2D flat pattern overlaps on itself.
Using the 3D fiber paths as a guide, a V-shaped dart should be created so the dart legs lie on the edge of
the region without fiber paths. The resulting dart looks like the image below.

V-Shape Darts to Eliminate Wrinkling (Bridging)
Notice how the fiber paths around the V-shaped dart now complete, and no voided regions are present.
A valid flat pattern can now be generated for this ply. Note that, based on the original design intent, you
need to create a small wedge shaped plies to fill the gap left by the darted region.

Valid V-Shape Dart Geometry for Wrinkling (Bridging)
2.9.3.2 Valid V-Shape Dart Geometry for Wrinkling (Bridging)
All valid V-Shape darts in Fibersim consist of two curves. In most cases these two curves form a v-shape.
The top of a V-Shape dart must form a vertex between the two constituent dart curves as seen below.
The length of each dart curve and the angle between each dart curve is defined based on user-inputted
points or user-inputted base curves.



3. Chapter 3: Advanced
3.1 Introduction
The advanced section provides advanced, preliminary design & automation tools, for the most complex
composites.
These objects provide a flexible and productive environment for digitally defining composite products
while automating many of the repetitive design, simulation and manufacturing tasks related to working
with composite parts. The software easily accommodates the demands of designing a wide variety of
composite parts and the complete range of materials and manufacturing processes used to create them.
These objects exploit the inherent advantages of many different composite design methodologies,
including:
• zone-based design
• ply-based design

Advanced (Application Browser)
3.1.1 Advanced (Application Browser)
The Elite package breaks down in the Application Browser as follows:

APP. BROWSER DESCRIPTION SECTION
Basic See Chapter 2.
Advanced Includes zone-based design & layer management.
• Design
Fibersim uses layers, for parts that are designed using
• Manufacturing zones. Layers allow you to apply dart groups and splice
groups, which are then used when plies are created
• Specification from the layer.
Design 3.2
Zone 3.2.1
Overlay Zone 3.2.2
Zone Transition 3.2.3
Stagger Editor 3.2.4
Transition Adjacency Vertex 3.2.5
Layer 3.2.6
Core Layer 3.2.8
Manufacturing 3.3
Splice Group 3.3.1
Darts 3.3.2
Dart Group 3.3.3
Design Station 3.3.4
Cutouts 3.3.5
Specification 3.4
Laminate Specification 3.4.1

Material Specification 3.4.2
Offset Specification 3.4.4
Stagger Profile 3.4.5
Laminate Regions 3.4.6

Design
3.2 Design
The process of zone-based design is used to create plies for zone-based parts.
1. Define the Zone and Material Specification objects.
2. Use the Zone-to-Layer Analysis functionality to create the corresponding Zone Transitions (ZTs) and
Transition Adjacency Vertices (TAVs).
You can customize ZTs and TAVs to meet design requirements. When a design change is made to zone
definitions, Zone to Layer update can update all corresponding data.

Zone
3.2.1 Zone
The zone object defines the constant gage areas of a composite part. A single zone can represent a
continuous constant gage area, or several zones can be defined.
NOTE: Zone objects must cover the laminate net area completely, leave no gaps, and must not overlap
themselves. If there are any voids or regions not covered by a zone, the utility will not function properly.
Laminate Specifications that drive each zone’s thickness and material composition are typically
imported, and the Zone to Layer Analysis combines adjacent zones with common material/orientation
combinations to produce Layers of coverage. Also, Zone Transition objects are created, which manage
Layers dropping off in a staggered ramp shape when going from a thicker zone to a thinner one.
NOTE: Downstream applications (like the Parametric Surface Offset utility) will respect Layers and Zone
Transitions resulting from either a topological zone or an overlay zone.
Fibersim does allow zone boundaries to be multi-domain. If they are, each individual domain must form
a closed loop. Though Fibersim does not require you to split individual curves to form a closed loop.
Zone objects use advanced boundary breaking behavior, allowing you to use a grid-based approach to
their design.

Zone
Standard Tab
MEMBER DESCRIPTION
Laminate Parent laminate of the zone. Zones inherit the layup surface
and boundary from the parent.
Note:
The group of zones defined on any given laminate
must account for all areas defined by the Net
boundary.
Rosette The rosette for the zone. Rosettes determine the fiber
directions of the material orientations associated to the
zones.
In general, only one rosette should be used for each set of

zones that cover a given laminate.
Zone to Layer Whether the zone has changed since the last zone analysis.
Status

Zone
GEOMETRY
Origin Defines the origin of the zone. By default, zones inherit the
origin from the rosette. However, in most cases you must
select or indicate a point on the laminate surface to define
the origin.
Note:
Origins must be defined on the inside of the zone
boundary.
Boundary Defines the zone’s boundary. By default, zones inherit the

laminate Net Boundary from the parent laminate. Curves
should form a closed loop.
Fibersim’s boundary generation behavior lets you use a

grid-based input for zone boundaries. The union of all zone
boundaries on a given laminate must cover the entire area
defined by the Net boundary.
MATERIALS
Laminate Link to the laminate specification for the zone.

Specification
Material
Specification
TARGETS
Target Ply Defines the target ply count for the zone. This member
Count should match the Actual Ply Count, once all Material Specs
are defined.
Note:
Used when Based On is set to “Target Ply Count”.
Actual Ply The actual ply count for the zone. This field is updated as
Count Material Specifications are added to the zone.
Note:
This member should match Target Ply Count, once all
Material Specifications are defined for a given Zone.

Zone
Core Sample Tab
MEMBER DESCRIPTION
Core Sample Type of core sample to be performed at the zone origin:

type
• Summary core samples provide component list, specified
orientation, and thickness data.
• Detailed core samples provide actual fiber orientation data at the

design station origin, by measuring results from the producibility
simulation against a reference rosette.
• Laminate rating core samples provide symmetry, balance, and

warpage calculations based on the specified orientation of each
found ply.
Max Distance that Fibersim uses to intersect surfaces from the zone origin.
Intersection By restricting which surfaces are used when core sampling the part,
Distance you can obtain core sample results for individual surfaces.
The distance will propagate in both the positive and negative surface
normal direction, from the design station origin.

Overlay Zones
3.2.2 Overlay Zones
Overlay Zone objects operate quite differently from topological zones With Overlay Zones, the Zone to
Layer Analysis does not combine the zones with like material/orientation combinations to form Layers.
Overlay zones are completely independent from one another (as well as from topological zones co-
existing in a model), so that the Layers and Zone Transitions resulting from overlay zones are isolated to
their respective Overlay Zone shape.
Unlike topological zones, Overlay Zones cover the entire laminate area and they can overlap. However, a
laminate can not contain both Overlay Zones and topological Zones. A part may be defined with both
types of zones by having a laminate for each, with a parent-child relationship between laminates.
NOTE: Downstream applications (like the Parametric Surface Offset utility) will respect Layers and Zone
Transitions resulting from either a topological zone or an overlay zone.
MEMBER DESCRIPTION

Overlay Zones
Laminate Parent laminate of the overlay zone. These zones inherit the layup
surface and boundary from the parent.
Rosette The rosette for the overlay zone. Rosettes determine the fiber
directions of the material orientations associated to the zones.
In general, only one rosette should be used for each set of zones
that cover a given laminate.
Zone to Layer Whether the overlay zone has changed since the last zone analysis.
Status
GEOMETRY
Origin Defines the origin of the overlay zone. By default, zones inherit the
origin from the rosette. However, in most cases you must select or
indicate a point on the laminate surface to define the origin.
Note:
Origins must be defined on the inside of the zone boundary.
Boundary Defines the overlay zone’s boundary. By default, zones inherit the
laminate Net Boundary from the parent laminate. Curves should
form a closed loop.
Fibersim’s boundary generation behavior lets you use a grid-based

input for zone boundaries. The union of all zone boundaries on a
given laminate must cover the entire area defined by the Net
boundary.
MATERIALS
Laminate Link to the laminate specification for the overlay zone.

Specification
Material Link to the material specification for the overlay zone.

Specification
TARGETS
Set to either Ply Count or Thickness.
Target Ply Count Defines the target ply count for the zone. This member should
match the Actual Ply Count, once all Material Specs are defined.

Overlay Zones
Note:
Used when Based On is set to “Target Ply Count”.
Actual Ply Count The actual ply count for the overlay zone. This field is updated as
Material Specifications are added to the zone.
Note:
This member should match Target Ply Count, once all Material
Specifications are defined for a given zone.
Target Thickness Total target ply thickness for this overlay zone.
Actual Ply Actual total ply thickness for this overlay zone.
Thickness

Zone Transition
3.2.3 Zone Transition
Zone Transitions determine how layers will drop-off from one zone to another.
Transitions contain Offset Specifications and Stagger Profiles that determine how the layer boundaries
will drop-off from zone to zone.
Zone Transitions are associated to layers, which determines the layer’s boundary shape. The Zone to
Layer utility automatically creates the necessary Zone Transitions that construct each layer. Using Offset
Specifications, you can manipulate the transitions as necessary. You can also create additional
transitions.
Zone Transitions are connected to adjacent Zone Transitions via the Transition Adjacency Vertex (TAV).
When a Zone Transition (ZT) object is selected in the object list view, a series of green lines highlights to
represent the Zone Transition.
The Transition Adjacency Vertices that are associated to the selected Zone Transition will be highlighted
as red circles or X’s. This provides a visual representation of the relationship between the ZTs and TAVs.

Zone Transition
Standard Tab
MEMBER DESCRIPTION
Laminate Defines the parent laminate of the zone transition.
Ply Count Displays the ply count difference between the

thicker and thinner zones.
Stagger Profile The Stagger Profile used when generating the

layer boundaries from the Zone Transition.
This will determine the drop-off profile or cross-

section of a Zone Transition through the thickness
of the composite part.
Offset Specification - Constant

Zone Transition
Will offset both transition end points a constant amount, so only one Offset
Specification is necessary to define the offset
Constant Offset Type
Offset Specification - Variable
Will offset each end point of the Zone Transition individually. Requires an Offset
Specification for both the start and end of the Zone Transition.

Zone Transition
Notice how the variable offset has a different offset distance on each end point
of the Zone Transition.
Initial Offset Adjustment Used to position the zone transition. Can be

positive or negative.
If the initial offset is already set in the offset spec

then this value will add or subtract from the
current zone transition position.
PLACEMENT DETAILS
Thicker Zone The thicker zone of the zone transition. Curves are
always offset from the thicker zone to the thinner
one.
Thinner Zone The thinner zone of the zone transition.
Adjacency Every Zone Transition must be connected to a

Transition Adjacency Vertex, at both ends. Each
Vertex 1 & 2 Zone Transition has an Adjacency Vertex 1 and 2.
There are two links since the Zone Transitions will
potentially be associated to two Transition
Adjacency Vertices.
Note:
When a TAV is linked to two or more
intersecting Zone Transitions, a red circle or
an “x” highlights for the vertex.
Adjacency Curves CAD-modeled curves to define the Zone

Transition’s drop-off curves. This member
overrides Fibersim-generated base transition
curves.
Note:
Clearing selected curves from here causes
the Transition to revert back to Fibersim-
generated Transition base curves.

Zone Transition
Options
The Options contain several other values you can set for the current zone transition:
MEMBER DESCRIPTION
Override Drop-Off If Fibersim-generated curves are not sufficient, you can

Curves override them by first selecting base curve geometry
(Adjacency Curve), and then selecting drop-off curves.
NOTE: Clearing selected curves makes Zone Transition

revert back to Fibersim-generated Zone Transition drop-
off curves.

Zone Transition
Geodesic Offset Whether to pull offset curves closer to the surface.

Curves
Alternative Whether to use an alternate geodesic offset method.

Geodesic Method
This option means that Fibersim will use a different
geodesic offset function for the creation of Zone
Transition offset curves.
This option is used if the default Zone Transition offset

method was creating undesirable results for a given Zone
Transition.
Segment Length Factor applied to the maximum segment length, used to

Factor subdivide the curve being offset.
Spine Curve Specifies the guiding curve.
Custom Plane Select a plane used to define a spine-based transition.
Generate Result Generates the result transition feature.

Feature
Generate Custom This button is only accessible when the offset

Offset specification is a materials ratio specification.
Specification
It will create a custom offset specification that is
equivalent to the material ratio specification at this ZT,
and link the ZT to the new specification.

Transition Extension along a Reference Curve
3.2.3.1 Transition Extension along a Reference Curve
Previous behavior for extending transitions was to extend each offset curve tangentially from its
endpoint. In cases of double curvature and large offset values, this could cause the resulting curves to
diverge and lead to undesirable results. Additionally, it is not always intuitive that the curve will extend
tangentially rather than following the original CAD curve used to define parent zone boundaries.
To address this, new behavior means that the "Extend Along Reference Curve" behavior can be enabled
by checking a box for the start or end of a transition.
In prior releases, enabling this behavior would extend to the end of the reference curve and offset its
entirety. This was both inconsistent with the traditional extension behavior and inefficient in the case of
long parts. This enhancement updates the behavior to better match the tangential extension.

Update This option will be checked by default. When enabled, the

Dynamically transition will behave is it did in previous releases.
When unchecked, changes to the trimming tab will not cause

a re-computation of the offset curves and their extensions
until Update or OK is pressed.
This can be helpful if multiple inputs need to be entered and

performance is a factor.
Select the method for zone transition curve manipulation.
At Start At End
Extend Transitions extend geodesically based on the tangent direction

Along at the end of the transition. In many cases, especially
Reference geometrically complex
Curve
parts, you will need it to extend along the path of the curve or
adjacent transition to get the correct shape.
This option allows for extension at the start following the CAD
curve used to define the corresponding zone boundary. All
affected layer boundaries should curve/close correctly once
they are recomputed
Initial The Zone Transition (ZT) extension distance, at the starting

Distance point of the base curve. The yellow arrow indicates the starting
point.
Positive values extend the ZT. Negative values trim it.
See example (a.) later.
Trim Method Increment

by Start
Incremental Distance - The incremental extension or
trimming of the ZT curves at the starting point. The yellow
arrow indicates the starting point. See example (b.) later.
Curve
Trimming Curves - Select the curves that will be used to trim

the zone transition curves. See example (e.) later.
Angle

Specifies the angle for trimming/extending the start point of

the zone transition.
At End At End
Extend Transitions extend geodesically based on the tangent direction

Along at the end of the transition. In many cases, especially
Reference geometrically complex parts, you will need it to extend along
Curve the path of the curve or adjacent transition to get the correct
shape.
This option allows for extension at the start following the CAD
curve used to define the corresponding zone boundary.
All affected layer boundaries should curve/close correctly once

they are recomputed.
Initial The Zone Transition (ZT) extension distance, at the starting

Distance point of the base curve. The yellow arrow indicates the starting
point.
Positive values extend the ZT. Negative values trim it.
See example (a.) later.
Trim Method Increment

at End
Incremental Distance - The incremental extension or
trimming of the ZT curves at the starting point. The yellow
arrow indicates the starting point. See example (b.) later.
Curve
Trimming Curves - Select the curves that will be used to trim

the zone transition curves. See example (e.) later.
Angle
Specifies the angle for trimming/extending the start point of

the zone transition.

a.) Initial Distance at Start of ZT (visual demo)
3.2.3.2 a.) Initial Distance at Start of ZT (visual demo)
The Zone Transition extension distance, at the starting point of the base curve. The yellow arrow
indicates the starting point.
Positive values extend the Zone Transition.

a.) Initial Distance at Start of ZT (visual demo)
Negative values trim it the zone transition.

b.) Incremental Distance at Start of ZT (visual demo)
3.2.3.3 b.) Incremental Distance at Start of ZT (visual demo)
The incremental extension (or trimming) of the Zone Transition curves at the starting point. The yellow
arrow indicates the starting point.
Positive values extend the Zone Transition. Negative values trim it.

c.) Initial Extension Distance at End (visual demo)
3.2.3.4 c.) Initial Extension Distance at End (visual demo)
The extension distance at the end point of the Zone Transition base curve. A yellow arrow indicates the
starting point, so the end point is opposite the yellow arrow.
Positive values

c.) Initial Extension Distance at End (visual demo)
Negative values

d.) Extension Distance Increment at End (visual demo)
3.2.3.5 d.) Extension Distance Increment at End (visual demo)
The incremental extension (or trimming) of Zone Transition curves at the Zone Transition end point.
The yellow arrow indicates the starting point, so the end point is opposite the yellow arrow.

e.) Trimming Curves (visual demo)
3.2.3.6 e.) Trimming Curves (visual demo)
Trim Curves, just as they say, trim zone transition curves. The image below illustrates using a single
continuous trim curve. The yellow arrow indicates the Start side of the zone transition.
Choosing a Single Continuous Curve (at Start)

Choosing a Single Continuous Curve (at End)
In some cases, Zone Transitions may need extending before being trimmed.
This image shows using Initial Extension Distance at End to first extend the Zone Transition past the
desired trim curve, and then a trim curve to finish the desired result.
If two trim curves are selected, Fibersim keeps the Zone Transition portion that is in between the two
curves.

Initial Extension Distance (with Trim Curve)
This image illustrates using two trim curves with an initial extension distance at the end of the Zone
Transition.

Two Trim Curves, with Initial Extension Distance

Stagger Editor
3.2.4 Stagger Editor
The Stagger Editor is a special cross-section-based user interface, which will show a cross section of the
layers dropping off at a given transition. Using this interactive interface, you can drag the layer
endpoints to the desired drop-off positions, allowing you to define the custom string of the transition
stagger profile.
The stagger editor always shows the given transitions' current stagger based on the laminate default
stagger or the local stagger profile. You can then immediately start dragging layers to new index
locations, or apply a pre-defined stagger shape.
Use the "+" and "-" buttons to zoom in and out to fit the display better. Note that you can also hold down
<control> and use the mouse wheel to zoom in and out like any traditional Windows application. <Ctrl +
A> also selects all layers at once.
Layer names/steps are listed on the left hand side, and layers are represented horizontally by a solid
colored line (regular transition) or a dashed line (interior transition).
For interior corners, a white circle symbol indicates an offset curve is being actively used. Offset curves
are represented by vertical dashed lines with the number at the top. (Note that when you select and
move either a line or a circle, it will highlight.)

Stagger Editor
TOOLBAR DESCRIPTION
BUTTON
Update With this is checked, the layers will update as you drag
Dynamically them to different locations. (On most models, it is easier to
leave this checked, but note that on large parts, the
computation might be time-consuming.)
Update Stagger This is only available when Update Dynamically is

and Layer unchecked. This option allows you to quickly make custom
Boundaries stagger changes to layers without waiting for each layer to
update. The layers update once this option is selected.
(This is a better choice for large models.)

Stagger Editor
MEMBER DESCRIPTION
Stagger Profile The stagger profile for the given zone transition.
Stagger Shapes This is the list of preset stagger shapes/profiles that

can be applied (same as the list in global stagger
profile).
Create New Stagger Creates a new custom Transition Stagger Profile

Profile object, to update the transitions stagger behavior.
Apply Stagger Shape This applies the previously set stagger shape to the
transition, and creates a new transition stagger
profile, if the transition did not previously have one.
Options (pop-up menu)
Layer Display
All Transition Layers Displays all layers using this transition.
Exclude Interiors Excludes any layers that use the transition as an

interior.
Collapsed Cross Collapses the cross section layers that do not use the
Section transition into single black lines.
Full Cross Section Displays all layers that exist at that transition,
whether they use it or not.
Layer Labels
You can set the GUI window to display layer names, sequence/step, or both.
Name Option to set whether the UI window displays layer

names.
Sequence/Step Option to set whether the UI window displays

sequence/step.
Orientation Option to set whether the UI window displays the

orientation.

Transition Adjacency Vertex
3.2.5 Transition Adjacency Vertex
Transition Adjacency Vertices are used to connect intersecting Zone Transitions to one another. You will
see a red circle or an “x” highlight that indicates the location of the Transition Adjacency Vertex.
Fibersim will also highlight green lines for the Zone Transitions that are associated to the vertex:
TAV001 (Transition Adjacency Vertex) is associated to ZT001 (Zone Transition), ZT002 and ZT003. This
tells Fibersim that these three ZTs intersect at TAV001.
Fibersim uses the Transition Adjacency Vertices and Zone Transitions to construct layer boundaries. If
connectivity of the Zone Transitions is not properly defined, Fibersim will not be able to construct the
boundaries.

TAVs also control where chamfers will be applied to layer boundaries. In some manufacturing processes,
such as Tape Laying, the machine has a minimum course length requirement. You can define a chamfer
on the outside corners of the layer boundaries, which satisfies the minimum course length requirement.
MEMBER DESCRIPTION
OVERVIEW
Referring Zone Displays the list of Zone Transitions that are linked to the given
Transitions TAV.
Vertex Transition The type of corner to be created at individual Transition Adjacency

Method Vertices.

Each option is described in its own section below.
Chamfer Interior Whether or not Fibersim will chamfer interior corners (Yes).
Corner
By default when a chamfer is applied to a Transition Adjacency

Vertex, Fibersim chamfers the outside corners of the layer
boundaries that pass through the Vertex. Origin and direction will
always be on the inside of the layer boundary.
Use Construction Fibersim will automatically create a construction transition at the

Transition given transition vertex. This is only valid for vertices that have two
transitions.

Non-Tangency
3.2.5.1 Non-Tangency
The Non-tangency option produces the default shape (non-tangent corner) at any given Transition
Adjacency Vertex.

Variable Length Chamfer
3.2.5.2 Variable Length Chamfer
The Variable Length Chamfer increases in size as layer boundaries are offset. Fibersim constructs it by
connecting the gap between the vertical and horizontal transitions with a straight line.
Since the first curve from each transition intersects one another there is no gap, and the corner results
in a non-tangency.
When ZTs are offset from a thicker gage to a thinner gage, a gap between the transitions is formed.
Fibersim constructs the Variable Length Chamfer by connecting this gap with a straight line.

Constant Length Chamfer
3.2.5.3 Constant Length Chamfer
The Constant Length Chamfers are constructed by creating a chamfer of constant length between two
adjacent Zone Transitions. Note that the Chamfer Length member must be set.
Fibersim first extends adjacent transitions until they intersect, then applies a Constant Length chamfer
to each layer. The offset spacing between layer boundaries in the chamfered area must increase.
MEMBER DESCRIPTION
Chamfer Length The chamfer length applied to the Transition Adjacency

Vertex.
Orient Vertex Whether or not Fibersim uses the rosette to map angles
with Rosette for the Transition Adjacency Vertex.

Constant Length Chamfer
When using Fixed Transition Chamfers, Fibersim sets this

to Yes, and makes it read-only.
Reference Angle Specifies the rosette angle to be used.

Minimum Length Chamfer
3.2.5.4 Minimum Length Chamfer
When a minimum chamfer length is required, and the offset spacing in the chamfered area must remain
at the distance specified in the Offset Specification, you should use a Minimum Length Chamfer. Note
that the Chamfer Length member must be set.
Fibersim will create the first chamfer using the Chamfer Length value, and then construct other
chamfers by maintaining a constant offset distance.
The Minimum Length Chamfer is constructed by creating the first chamfer per the Minimum Length
value. Subsequent chamfers are created by maintaining the offset distance, which increases chamfer
length as the layer boundaries are offset.
MEMBER DESCRIPTION

Minimum Length Chamfer
Chamfer The length of the chamfer for the TAV.

Length
Orient Vertex Whether or not Fibersim uses the rosette to map angles for the
with Rosette Transition Adjacency Vertex.
Note:
When using Fixed Transition Chamfers, Fibersim sets this to Yes,
and makes it read-only.
Reference Specifies the rosette angle to be used.

Angle
Chamfer Drop- If at a given Transition Adjacency Vertex, the Zone Transition has
Off Control different offset distances then you can choose to use the larger or
smaller offset distance for the chamfer area.
You can also set the drop-off distance by either the constant values or
using the multiple of thickness value.
• Larger Drop-Off – larger offset distance for the chamfer.
• Smaller Drop-Off – smaller offset for the chamfer.
• Constant Drop-Off – chamfer will drop off according to the value

displayed in Constant Drop-Off
• Multiple of Thickness – Fibersim will multiply the cured material

thickness by this number (displayed in Multiple of Thickness) for
the drop off
Constant Drop- The chamfer will drop off according to the value displayed here when
Off the drop-off is set to Use Constant Drop-Off.
Multiple of Fibersim will multiply the cured material thickness by this number
Thickness when the drop off is set to Use Multiple of Thickness.
Layers Per Number of layers per drop-off.

Drop-Off

Fixed Transition Chamfer
3.2.5.5 Fixed Transition Chamfer
Fixed Transition Chamfers fix the Zone Transition length with the larger spacing, then use transition end
points to extend the chamfer. The direction that the chamfer extends is based on the Reference Angle
value.
Fibersim extends the chamfer from the end point of the larger transition until it intersects the other
transition, and uses the rosette to map the chamfer reference angle. This illustrates how Fibersim
constructs a Fixed Transition Chamfer.

Minimum Course
3.2.5.6 Minimum Course
MEMBER DESCRIPTION
Chamfer Length The chamfer length applied to the TAV.
Minimum Course Links the TAV to a Minimum Course Vertex object.

Vertex Fibersim then applies appropriate Minimum Course
behavior.
Orient Vertex Whether or not Fibersim uses the rosette to map angles
with Rosette for the Transition Adjacency Vertex.
Note:
When using Fixed Transition Chamfers, Fibersim sets
this to Yes, and makes it read-only.
Reference Angle Specifies the rosette angle to be used.

Point to Point
3.2.5.7 Point to Point
Point-to-Point
This chamfer type option will connect the end points of the zone transitions, with no influence from
interior transitions.

Construction Transition
3.2.5.8 Construction Transition
Construction Transition
When this option is enabled, Fibersim will automatically create a construction transition at the given
transition vertex. This is only valid for vertices that have two transitions.

Layers
3.2.6 Layers
Fibersim uses layers for parts that are designed using zones. (Layers are parent objects in the creation of
plies). Fibersim creates layers from zone definitions.
You can then create plies directly from the layer object. Layers allow you to apply dart groups and splice
groups, which are then used when plies are created from the layer. Note that if a ply is spliced via a
layer, the layer holds on to the original or pre-spliced shape.
In zone-based design, Fibersim updates the layer boundary when changes are made to objects that
affect the boundary. When a layer is the parent of a ply, then members that are shared between the ply
and the layer can only be edited in the layer. When changes are made to the layer, Fibersim updates
corresponding members in the ply.
Note that you can manually edit Net Boundaries and Net Holes in the layer, and select curves. When
overriding a layer boundary, both Net Boundary and Net Hole members must also be overridden. Net
Holes do not need to be overridden if there are no holes in the layer being overridden. You can then
clear manually selected curves, to get back to the Fibersim-created boundary.

Layers
MEMBER DESCRIPTION
Laminate Parent laminate of the layer. Layers automatically inherit

their layup surface and boundary from the parent.
In zone-based design, a layer’s laminate is obtained from

the zones used to define the layer.
Material Material that the layer is made from. Layers that are
defined from a zone-based design inherit their material
from the material spec.
Note:
It is not recommended changing a material from
within the layer object. Make appropriate changes to
material spec objects, and then run a zone-to-layer
update.
The chosen material will determine the drapability

characteristics, thickness, areal weight, cost, and material
bolt width for the ply.
Rosette Fiber angles are measured relative to this rosette.
Specified Defines the layer’s orientation based on the rosette. For

Orientation zone-based design, orientation is inherited from the
material spec.
Make appropriate changes to material spec objects and

then run a Zone-to-Layer update, to ensure that layers are
accurately generated based on the zone definitions.
Sequence Defines the layer’s sequence in the composite part

stackup. A layer sequence value is inherited by any plies
generated from it.
Step The layer’s step number within composite part stackup.

Inherited by any plies that are generated from the layer.
Drop-Off Order Defines the order that a layer is assigned an index curve
for a given Zone Transition. Since layers often use many
ZTs, the position of an index curve for a layer can change
from ZT to ZT.

Layers
Note:
It is recommend to use “No Pre-Sorting” in the Drop-
Off Order Pre-Sorting member, in the Laminate
form.
Default value is 0, which means Drop-Off Orders are not

being used (Stagger Profile is used.) To use Drop-Off
Order, you must define a Linear Ascending Stagger Profile
object and link it to all Zone Transitions.
NOTE: This member overrides Stagger Profiles for each ZT.
Zones Zone objects, in combination with transition object, is how

a layer’s boundary gets generated.
For zone based design, zones are associated to layers

when the zone-to-layer utility is run.
Transitions Transition objects, in combination with zone objects, is

how a layer’s boundary gets generated. Transitions
determine how layers/plies drop-off from regions of gage
or thickness changes.
Material This field will be automatically applied to any existing or

Specifications new layer objects.
This field will only be populated once a Zone To Layer

update is run.
Origin Select the origin point for the layer, on the 3D surface.
Net Boundary The boundary feature, generated with utilities that publish
data to a new model or a new laminate:
• Merge Models
• Surface Transfer
• Manufacturing Laminate Creation utilities
Net Holes Behaves the same as Boundary Feature, but holes are
linked, instead of the boundary.
Display Highlights plus-one offset boundary (in Blue).

Layers
Generate Generates a CAD curve, representing the plus-one

boundary for the given layer.
Manufacturing Select the manufacturing process for this component.

Process
Splice Groups Select a splice group object, to splice the target layer. Once
a ply has been created from a layer, you can then splice it.
Splice Status Current splice status of the layer’s plies. Status changes to
Out-of-date when a change is made that requires re-
splicing.
Dart Groups Select dart group object to apply darts to plies created
from the layer.
Transition Management
Transition Status If a layer successfully generates, ‘OK’ is displayed. If not, it

is displayed in red, and ‘Failed’ is displayed.
Centerline Centerline curve for this layer, used to generate course

objects.
Generate Generates the course on the centerline, using the selected

Centerline centerline.
Course

Core Layer
3.2.7 Core Layer
Core Layers are used when a zone-based design must contain a core. They are generated during the
Zone-to-Layer Analysis, similar to how layers are generated, when you have included cores in Material
Specs.
When defining cores, enter a total core thickness value. This value is transferred to the Top Thickness
value of the Core Layer. If using a double bevel core, change the thickness in the Core Layer to represent
the double bevel core. When core is generated via the Zone-to-Layer Analysis, Fibersim generates a
single bevel core.
Once a Core Layer is setup, you can generate Virtual or Virtual Variable Core objects. The core layer will
be the parent of the core (similar to layers’ and plies’ relationship).

Core Layer
MEMBER DESCRIPTION
Laminate The parent laminate. Core Layers automatically inherit

their layup surface and boundary from the parent
laminate.
Material Material that the Core Layer is made from. Core Layers
defined
from a zone-based design inherit the material from the

material
specification.
Sequence The Core Layer’s sequence in the part stackup.
Step The Core Layer’s step number within the part stackup.
Zones The zones used to generate this object.
Material This field will be automatically applied to any existing or

Specifications new core layer objects.
This field will only be populated once a Zone To Layer

update is run.
Core Type Select the proper core fro which to generate the layer.

Manufacturing
3.3 Manufacturing
3.3.1 Splice Group
Splice Groups allow you to define a group of splice curves to be used to splice a group of layer-based
plies. Most often the Splice Groups are created based on ply orientations that they will be applied to.
Based on the number of layers that the Splice Group is applied to, Fibersim will create all of the
necessary offset curves.
Splice Groups use Offset Specifications to drive how the Splice curves are offset, and let you define butt
splices or overlap splices.
MEMBER DESCRIPTION

Splice Group
Laminate The laminate that will be used for the Splice Group.
Orientation Specifies the orientation of the layers that the Splice Group will be
applied to.
Splice Curves Specifies curves for the Splice Group. Select the curves in the exact
order in which the plies are going to be spliced. For example, if the
part is going to be spliced from left to right, pick the left most curve
first, then continue left to right
NOTE: Splice Curves must be on the laminate surface, and must

break against the laminate Net Boundary.
Stagger Profile Specifies the Stagger Profile used when splicing the plies.
Determines how plies splice through the thickness of the part.
Offset Specifies the Offset Specification for offsetting Splice Curves. This
Specification value determines how far apart the Splice Curves will drop-off
through the part thickness.
Overlap Based On Specifies whether the Overlap Distance is based on:
• Distance – input an Overlap Distance value
• Material Thickness – select a Material, then input a Multiple

of Thickness, which is based on the Material’s Cured Thickness.
Overlap Region Allows you to specify an overlap region. You should choose a region
that defines the area where the overlap should take place.
With an overlap region, Fibersim creates butt splices outside of the

region and overlap splices on the interior of the region.
Recess Distance Defines the recess distance from the Overlap Region that the
overlap splice will begin.
For example, you often define the Overlap Region as the edge of a
core, but do not want the change from a butt splice to an overlap
splice to begin directly on the core edge.
Shift Splice Base Whether or not Fibersim will shift overlap splices, to maintain proper
Curves material width.

Splice Group
Check Material Splice only those plies that are wider than the material width.
Width
Match Step Layers that link to this splice group will get the same curve, if they
have the same step.
Geodesic Offset Whether to pull the offset curves closer to the surface.
Curves
Alternative Whether to use an alternative geodesic offset method.

Geodesic Method
Ply Name This option allows you to specify a separator character for spliced
Separator plies.

Darts
3.3.2 Darts
Full details about darts are discussed in the Darts section in Chapter 2.

Dart Group
3.3.3 Dart Group
Dart Groups allow you to apply a sequential group of darts to plies that are layer-based. Some composite
parts use a pattern of darts that need to be applied to a group of plies.
In these cases. you define a Dart Group and then assign it to the necessary layers.
When you create plies from layers, Fibersim applies the correct darts to the correct ply.
MEMBER DESCRIPTION
Laminate The laminate to be used for the Dart Group.
Orientation The orientation of the layers that the Dart Group will be applied
to.
Darts Specifies darts to be applied to the plies. The order of the darts is
determined by the order that the darts are linked.
When the Dart Plies button is selected for a group of Layers that
use a given Dart Group, Darts are applied based on the dart
sequence, and the layer sequence.

Dart Group
The layer with the lowest sequence will be given the dart with
the lowest sequence.

Design Station
3.3.4 Design Station
Full details about darts are discussed in the Design Station section in Chapter 2.

Cutouts
3.3.5 Cutouts
Full details about darts are discussed in the Cutouts section in Chapter 2.

Specifications
3.4 Specifications
3.4.1 Laminate Specifications
Laminate Specifications are used to group material specs, that define the material characteristics of the
constant gage areas on a composite part.
When using Laminate Specs for a zone-based design, it is recommended defining a spec for the unique
constant gage areas on the composite part.
For example, some composite parts may require 200 or more zones, however there may only be 20
unique gage areas. This means you only have to define 20 unique Laminate Specifications, and then link
them to all of the appropriate zones.
MEMBER DESCRIPTION
Color Select a color to use when highlighting the zones.

Laminate Specifications
Ply Count Total ply count for all Material Specs that have been added
to the Laminate Specification. Fibersim updates this value
as ply counts increase or decrease.
Note:
This member is read only.
Ply Thickness A total ply thickness for all material specs that have been
added to the Laminate Specification. Fibersim updates
this value as the ply thickness increases or decreases.
Note:
This member is read only.
Material Lists all Material Specs linked to this Laminate

Specifications Specification.

Material Specifications
3.4.2 Material Specifications
Material Specs define a material, orientation, and ply count:
• When used for zone definitions: the combination of all Material Specs applied to a given zone fully
defines the zone’s gage characteristics.
• When used for Design Station purposes: the combination of all Material Specs applied to a given
Design Station verifies laminate characteristics at the Design Station location.
Material Specs are usually used for zone definitions. As a rule, only unique Material Specs can be applied
to a zone. Most composite parts require many zones, which makes this rule tedious for these types of
parts.
However, material specs can also be applied to Laminate Specs, which then can be applied to multiple
zones. When using Material Specs for zone-based design, it is recommended using Laminate Specs.
Each one should have unique Material Spec that describe the gage characteristics of a zone or multiple
zones. It is recommended having a Laminate Spec define the unique constant gage area on the
composite part. This provides the most efficient use of the material specification for a given part.

Material Specifications
MEMBER DESCRIPTION
Parent Zones, Laminate Specs, and Design Stations can all be

parents of a material specification.
Material Material used for the material specification.
Orientation Orientation value for the material.
Ply Count The ply count for the Material Specification. Must be an
integer value, that is greater than or equal to 0 for the ply
count.
Step Specifies the Material Specification’s position in the

stackup.
Drop Off Order Select the drop off order to be used for the layer created
from this material specification.
Core Thickness The thickness of the core for a given Material Spec. You can
enter the core thickness for each Material Spec since the
same database entry for a given core material may be used
for a variety of core thickness. This value is used when the
core layer is generated.
Analysis Displays the links to the analysis components that were

Components created in the import process. Note that deleting the
import will clear this field.
See the note below for more details.

Notes on Material Specifications
3.4.3 Notes on Material Specifications
Layers created from Material Specifications with Analysis Components will be created with one Analysis
Component each:
• If the number of layers to be created is greater than the number of Analysis Components one or
more layers will not contain analysis data.
• If the number of layers to be created is less than the number of Analysis Components one or more
Analysis Components will not be used.
If there is a list of Analysis Components, and the Material Specification's material and thickness values
are changed such that the number of plies in that Material Specification no longer matches the number
of Analysis Components in the list, the user is notified via a warning.
A Material Specification created via "Create Based On" will not inherit the source Material Specification's
analysis data.
Multiple Material Specifications used by a single Zone cannot link to the same Analysis Component.
If a Material Specification with Analysis Components is linked (by user) to an object other than an
Overlay Zone the user should be warned that the link to analysis data will be broken.
Layers will only be assigned Analysis Components if the Material Specification is linked directly to the
Overlay Zone.

Offset Specifications
3.4.4 Offset Specifications
Offset Specifications tell Fibersim how a set of curves should be offset. Offset Specifications are used in
the Zone Transition (ZT) and Splice Group Objects.
When used to customize the behavior of a ZT, the Offset Specification is a power tool. By using them,
ZTs can be moved so ramp areas are positioned strategically. This allows you to use a grid-based design
approach and then customize the ZTs to meet your design needs.
Offset Based On
Specify whether the offset distance will be inputted based on:
• Distance
• Material Thickness
• Total Distance

For example, if there are 10 offset curves and the Total Distance is 1 inch, Fibersim equally spaces all 10
curves to 1 inch of the base curve.
MEMBER DESCRIPTION
Offset Based On Whehter the offset distance is based on:
• Distance
• Material Thickness
• Total Distance
Offset Distance The primary or first offset distance along the edge.
Plies Per Drop- Number of layers/plies to be dropped-off at each ZT or

Off Curve Splice Curve. Input individual values for:
• Base Curve

• First, Second or Third offset
Use Additional Check the Use... option to make this active.

Distance
This is the offset distance used for additional curves.
Distance Specifies the transition position, values can be positive or

negative real numbers.
Material Thickness
Multiple of Specifies the offset distance as a multiple of the chosen

Thickness material's thickness. The values entered will be multiplied
by the materials thickness value to determine the offset
spacing.
Material Material to use.

Advanced Positioning Options (pop-up menu)
3.4.4.1 Advanced Positioning Options (pop-up menu)
The Advanced Positioning portal lets you select the type of offset to use for the zone transition. Offsets
to select include:
• Initial Offset – enter a positive or negative offset on zone transition curves. (A.)
• Ramp Centered Offset – similar to Center Based Offset, but Fibersim centers the zone transition
based on the ply ramp instead of number of drop-off curves. (B.)
• Center Based Offset – center zone transition curves along zone boundary. (C.)
• Distributed Offset – input a gap distance on the inner (thicker) and outer (thinner) side of the
zone boundary. (D.)

A.) Initial Offset
3.4.4.2 A.) Initial Offset
MEMBER DESCRIPTION
Initial Offset - Based on Distance
Distance Initial offset distance value.
Initial Offset - Based on Material Thickness
Multiple of Specifies the distance that a Zone Transition will be

Thickness offset from the zone boundary. The value is a multiple
of material thickness.
A positive value offsets curves to the thinner zone,

negative values offsets them to the thicker zone.
Material The material to use.

B.) Ramp Centered Offset
3.4.4.3 B.) Ramp Centered Offset
This options centers the zone transition based on the ply ramp.
This behaves like a Center Based Offset, but is offset an additional ½ Offset Distance toward the thinner
zone.
When you set the value for the Initial Offset Distance (distance that a Zone Transition is offset from the
zone boundary), a positive value offsets curves toward the thinner zone, negative values to the thicker
zone.

C.) Center Based Offset
3.4.4.4 C.) Center Based Offset
Using this option, if there are an even number of curves, the center offset is split on each side of the
zone boundary. If there are an odd number, it lies directly on top.

D.) Distributed Offset
3.4.4.5 D.) Distributed Offset
The Distributed Offset lets you define an Inner and Outer Gap distance. The number of curves generated
for the Gap is determined by the Inner Offset Percentage.
MEMBER DESCRIPTION
Inner Offset The percentage of curves to be offset to the inside (thick

Percentage side) of the Inner Gap distance.
Inner Gap The Inner Gap distance in between Zone Transition curves
and the zone boundary curve. Distance is always toward
the thicker zone.
Outer Gap The Outer Gap distance in between the Zone Transition
curves and the zone boundary curve.
This distance is always toward the thinner zone.

Advanced Spacing Options
3.4.4.6 Advanced Spacing Options
The advanced spacing options consist of four choices:
• Distance Based Offset (see a. below)
• Total Distance Based Offset (see b. below)
• Material Thickness Based Offset (see c. below)
• Custom Based Offset (see d. below)

a.) Distance Based Offset options
3.4.4.7 a.) Distance Based Offset options
This type of offset defines the distance between offset curves directly.
MEMBER DESCRIPTION
Offset Definition Whether the Offset Specification will be:

a.) Distance Based Offset options
• Single Linear
• Double Linear
• Triple Linear
MEMBER DESCRIPTION
Offset Distance Total to offset distance value.
Drop-Off Curve count based on either Percentage or Curve Count:
Percentage
Percentage of Curves Percentage of offset curves that use the offset

distance.
NOTE: If Offset Type is set to “Single Linear”,

percentage is always 100.
Curve Count
Number of Curves The number of offset curves that use the offset
distance.
NOTE: If Offset Type is set to “Single Linear” the Offset

Distance is applied to all curves in the Zone Transition.

b.) Total Distance Based Offset options
3.4.4.8 b.) Total Distance Based Offset options
This type of offset defines the length of the entire ramp.
MEMBER DESCRIPTION
Total Distance Total distance value.
Divide By Ply Count Plus This option will divide the total distance by the
One number of plies, then add one.

c.) Material Thickness Based Offset options
3.4.4.9 c.) Material Thickness Based Offset options
This type of offset defines the distance between offset curves, as a multiple of a single material
thickness. The Offsets portal opens to the window below:

c.) Material Thickness Based Offset options
MEMBER DESCRIPTION
Offset Whether the Offset Specification will be:

Type
• Single Linear – all offset curves controlled by the Offset
Specification will have the same Offset Distance.
• Double Linear – provide two different Offset Distances.
• Triple Linear – provide three different Offset Distances.
Select an option and the appropriate section becomes active

below.
MEMBER DESCRIPTION
Multiple of Thickness Specifies the offset distance as a multiple of the

chosen material's thickness.
Drop-Off Curve count based on either Percentage or Curve Count:
Percentage
Percentage of Curves Percentage of offset curves that use the Single/First

Offset distance.
NOTE: If Offset Type is set to “Single Linear”,

percentage is always 100.
Curve Count
Number of Curves The number of offset curves that use the Single/First
Offset distance.

d.) Custom Based Offset options
3.4.4.10 d.) Custom Based Offset options
This type of offset lets you set custom-based offset values.
MEMBER DESCRIPTION
Offsets The list of distances, between each offset curve. Each

value should be separated by a space.
Plies Per Drop-Off Comma-separated list of the number of plies, for each
Curve drop off curve.

e.) Material Ratio Offset
3.4.4.11 e.) Material Ratio Offset
The Material Ratio Offset type lets you generate an offset specification based on more than one material
thickness. You can set the Multiple of Thickness and a number of plies per drop-off. This will disable the
other offset distance and plies-per-drop-off members.
When a Material Ratio offset specification is linked to a zone transition, the transition will compute its
offset curves according to the multiple of material thickness, relative to the layer, that dropped off
previously.
PLEASE NOTE: Because the offset distances are based on the layer stackup,
changing the drop-off order (directly or by changing the step value, for
example) will require zone transitions and all the layers on them to be
recomputed.
MEMBER DESCRIPTION
Multiple of Set the multiple of thickness value.

Thickness
(i.e. set to 20 to achieve a ramp based on a 20:1
material ratio)

e.) Material Ratio Offset
Plies per Drop-Off Comma-separated list of the number of plies, for each
Curves drop off curve.

Stagger Profile
3.4.5 Stagger Profile
Stagger Profiles are used when generating the layer boundaries from a Zone Transition. This will
determine the drop-off profile or cross-section of a Zone Transition through the thickness of the
composite part.
These profiles are used with the Zone Transition Stagger Editor utility.
MEMBER DESCRIPTION
Stagger Profile Specify the pattern for this profile. Either Linear Ascending,
Pattern Linear Descending or Custom.
Custom Pattern Specifies the through-the-thickness order in which the

offset curves are assigned.
Repeat After This value specifies the limit on the number of curves to be
offset, for linear and symmetric stagger profile patterns.

Laminate Regions
3.4.6 Laminate Regions
Regions have a logical link to Darts, Dart Groups, and Splice Groups. Fibersim will report if any Darts or
Splices violate the No Dart or No Splice Regions.
These regions are designed to alert you when a given region has been violated.
In general, regions enrich the CAD model with non-geometric information that better describes the part
being designed.
• Regions where no splicing should occur
• Regions where no darting should occur
• Regions where no drop-offs should occur
• Surface Treatment Regions
• Mating Surface Regions

List of Laminate Region objects
3.4.7 List of Laminate Region objects
The following is a list of region object windows you can use within Fibersim:
REGION OBJECT DESCRIPTION
Overlap Splice You can define an area on the part where overlap splices should be
Region defined. In some cases, you might like to apply a butt splice on the
edge of the part, and then switch to an overlap splice for a given
region of the part.
You can do this by linking the Overlap Splice Region to the Overlap
Region member in the Splice Group.
No Splice Defines regions where splices are not allowed.

Regions
Fibersim presents a warning message if you attempt to splice through

these areas.
No Dart Allows you to define a region where darts are not allowed.
Regions
Fibersim presents a warning message if you attempt to dart through

these areas.
No Drop-Off Defines regions where drop-offs are not allowed.

Regions
Surface Surface treatment regions are regions on the given surface that will
Treatment receive specific surface treatments, based on your standards.
Regions
On some parts, the surface finish on all or certain areas of the part
needs to be done in a specific way.
Mating Surface Mating Surface Regions are regions on the given surface, used to mate
Regions additional components.
NOTE: You may have special rules in regards to the treatment of ply
drop-offs and splices in these regions.



4. Chapter 4: Wind (Interfaces)
4.1 Introduction
IMPORTANT: You need the proper bundle value set

(FIBERSIM_LICENSE_BUNDLE) and have the proper license to use Wind Blade
functionality.
Chapter 1 includes a full list of bundle values.
The laminate structure for most wind blades can be derived from a few reference curves and the offset
values from those curves. As such, Fibersim offers the ability to define all the geometry and plies in a
blade by importing a spreadsheet using the Wind Blade Design Import (WBDI) utility. This utility is
discussed later in this chapter.
This utility provides a link to several reference curves in the CAD system. Based on a specified region and
several parameters defined in the spreadsheet, the utility will create 4-sided plies and cores, or layers
and core layers. The Wind Blade module provides access to all objects necessary to design a wind blade
within Fibersim.

Objects used in wind blade production
4.2 Objects used in wind blade production
This is a list of the objects you can use during wind blade production.
4.2.1 Design
4.2.1.1 a) Laminate
Note:
Details of the laminate object are discussed in Chapter 2, section 2.3.

b) Rosette
4.2.1.2 b) Rosette
Note:
Details of the rosette object are discussed in Chapter 2, section 2.4.

c) Layer
4.2.1.3 c) Layer
Note:
Details of the layer object are discussed in Chapter 3, section 3.2.5.

d) Core Layer
4.2.1.4 d) Core Layer
Note:

Manufacturing
4.2.2 Manufacturing
4.2.2.1 a) Ply
Note:

b) Course
4.2.2.2 b) Course
See the next section for details.

c) Core
4.2.2.3 c) Core
Note:

d) Splice Group
4.2.2.4 d) Splice Group
Note:

e) Design Station
4.2.2.5 e) Design Station
Note:

f) Cutout
4.2.2.6 f) Cutout
Note:

Course
4.3 Course
Course objects are only used in Wind Blade production. Courses will be linked to its 3D boundary, 3D
centerline, flat pattern and 3D centerlines for the adjacent courses (one on each side). A course object
also inherits the seq/step, material, orientation and rosette from its parent layer.
Running the Course Generation utility (found on the layer object toolbar and under Tools > Operations)
creates the new vourse objects.
SPECIAL NOTE: A course object has a very similar look and feel to the ply object.
The main differences are that a course has a Centerline, which is used to define
the course boundary. You can also select left and right adjacent course
materials.

Course
MEMBER DESCRIPTION
Parent Specifies the parent object.
Material Select the material from which the course is made.
Rosette Fiber angles are measured relative to this rosette.
Specified The course’s orientation, based on the selected rosette.

Orientation
Actual The actual orientation of the course. If the orientation is

Orientation defined using a fiber direction curve, the orientation of
the fiber direction curve is measured against the rosette,
to determine the actual orientation.
Sequence Determines the course’s sequence in the part stackup.
Step Determines the course’s step number in the part stackup.
Origin
Centerline The centerline of the layer must span the parent layer
boundary, and have some part of it inside the net
boundary.
Constraint Curve This curve is necessary when the centerline is outside the
laminate net boundary (used to guide the simulation).
Guiding Course If the course centerline ends, the guide course will be
used to propagate the remaining simulation. This
function is intended for courses at the edge of the part
whose centerline is shorter than the rest of the course.
Adjacent Course This value is the overlap distance between a course, and
Overlap any adjacent courses.
Generate Right/ Check this option and select a material.

Left Adjacent
Centerline
Right/Left Material for the adjacent course.

Adjacent Course
Material

Course
Simulation Tab
MEMBER DESCRIPTION
Simulation Select the type of simulation to run on a ply-by-ply basis.

Method Either Traditional, Curvature Adaptive, NCF or Spine.

Course
Fiber Spacing Controls simulation cell size. Default of 1.0 is usually

Factor sufficient for an accurate simulation, and to generate an
accurate flat pattern.
Origin The point on the 3D surface where the layup begins.
Actual Actual or measured orientation (if different from the

Orientation specified orientation).
Propagation Direction of the simulation cell propagation:

Direction
• Parallel
• Bias (–WeaveAngle/2)
• Bias (+WeaveAngle/2)
• Orthogonal
Simulation An alternate simulation surface, used to eliminate holes

Surface from the producibility simulation.
First Stage Simulation will run in this region first, prior to flattening
Region the remainder of the course. Must consist of a set of
closed curves.
Constant Offset Offsets the simulation/flat pattern from the tool.

Mode

Wind Blade Import (utility)
4.4 Wind Blade Import (utility)
Manually creating a ply-based design of a wind blade is extremely time-consuming, due to the number
of plies. You can now set parameters in an excel spreadsheet, with minimal geometry input, to describe
the plies. That file can then be imported into Fibersim using this utility.
This utility provides a link to several reference curves in the CAD system. Based on a specified region and
several parameters defined in the spreadsheet, will create 4-sided plies and cores, or layers and core
layers. The Wind Blade module provides access to all objects necessary to design a wind blade within
Fibersim.
You can access this from: File > Import > Wind Blade Design Import

Wind Blade Import (utility)
MEMBER DESCRIPTION
Laminate The parent laminate, for the imported plies and rosettes.
Rosette Fiber directions will be measured relative to this rosette.
Input File File containing the data, to be used in the wind blade design.
Leading Edge This curve represents the leading edge of the part.
Trailing Edge This curve represents the trailing edge of the part.
Spar Cap The centerline that runs the length of the spar cap area.
Centerline
Spine Specifies the wind blade spine, to be used as an axis.
Result Type Whether Fibersim will create layers or plies.
Add Prefix to Names
Prefix In order to track the ply name independently from the layup
sequence, there spreadsheet columns called "Step" and "Sequence".
In the Step column, plies/layers are named based on the "Ply"

column (i.e. "1" becomes "PLY001" or "LYR001", "14b" becomes
"PLY014b" or "LYR014b").
This option lets you add the prefix, to specify the full ply name in
the spreadsheet. The "PLY" or "LYR" prefixes are used as the defaults.
You can also specify your own prefix, rather than the defaults.
Reverse Spine Reverses the orientation direction of the spine.

Direction
Segment Length Controls the number of points, for the creation of blade geometry.
Factor
Step Increment The step increment value.

Excel spreadsheet parameters
4.4.1 Excel spreadsheet parameters
This is a list of the parameters used in an imported spreadsheet:
• Ply - Name of the ply
• Step - The number in the stackup
• ZStart, ZEnd - Boundary distances from the root
• Width - Defines edge boundaries for certain regions
• Orientation - The Orientation value to be imported
• Material - The Material to be imported
• Region - Type of ply, determines behavior of import (mapped to the Function field)
• StartOffset, EndOffset - Offset values from the region curve
• StartEdgeOffset, EndEdgeOffset - Offset from the Leading/Trailing edge for the core
• StartAngle, EndAngle - Angles Z-boundaries from the ply centerline normal
• Thickness - Used for cores only

Workflow - Geometry
4.4.2 Workflow - Geometry
In Fibersim, links must be made to:
• The laminate and rosette
• Leading Edge Curve
• Trailing Edge Curve
• Spar Cap Centerline
• Spine
Based on the Region field, the WBDI utility creates all plies/layers, core, and the associated geometry.

Results - Created Geometry
4.4.3 Results - Created Geometry
• Spine Intersect curves - planar Z-boundaries normal to the spine
• Curve Offsets - geodesic offset curves from region curves
• **_MWL_## - material width curves used for ply/layer boundaries
• **_CENTER_## - curves used for ply/layer centerlines
• Angle Cuts - angled Z-boundaries defined from the centerline normal
• Origins - defined along the centerline
• Core Boundaries - closed curves for the core

Region Details (w/ images)
4.4.4 Region Details (w/ images)
The unique regions supported by the WBDI utility are: Leading & Trailing Edge, Spar Cap, Leading
&Trailing Core, Leading & Trailing Var and Full Body.
Each of these regions is mapped into the Fibersim object's Function field to aid in working with the data
once imported.

Leading & Trailing Edge
4.4.4.1 Leading & Trailing Edge
Ignored fields:
• StartEdgeOffset
• EndEdgeOffset
• Thickness

Spar Cap
4.4.4.2 Spar Cap
Ignored fields:
• StartEdgeOffset
• EndEdgeOffset
• Thickness
Angle Cuts (StartAngle and EndAngle) - Leading/Trailing Edge and Spar Cap only
The angle is measured from the orthogonal of the ply centerline. If it is blank, or a non-numeric value,
the ply will be trimmed to the spine intersection (ZStart/ZEnd).

Leading and Trailing Core
4.4.4.3 Leading and Trailing Core
Ignored fields:
• Width
• StartAngle
• EndAngle

Leading and Trailing Core
4.4.4.4 Leading and Trailing Core
Ignored fields:
• Width
• StartAngle
• EndAngle
• Thickness

Full Body
4.4.4.5 Full Body
Ignored fields:
• StartEdgeOffset
• EndEdgeOffset
• Thickness
• Width
• StartOffset
• EndOffset
• StartAngle
• EndAngle

Full Body

Full Body

5. Chapter 5: Automated Deposition Design
(ADD)
5.1 Introduction
The Automated Deposition Design (ADD) environment provides design tools that aid those who use
automated deposition machines. This includes Fiber Placement and Tape Laying machines. Since these
machines often have minimum course length restrictions, the ADD aids in applying necessary boundary
alterations, to account for the restriction.s
The ADD also aids in the ramping down of extended ply boundaries. When using automated deposition
machines, it is not desirable to have a large step from the material edge to the tool surface. If this step
does exist, the machine will often lift up layers of material that have already been deposited on the tool.

Extended Ramp
5.2 Extended Ramp
When using automated deposition machines, you may want to prevent having a large step from the
material edge to the tool surface. The Extended Ramp object lets you automatically ramp down the plies’
extended boundaries.
Extended ramps must be applied to the necessary plies, and link to the plies under the “Extended
Geometry tab” (in the Ply form).
You should only apply Extended Ramp objects to fullbody plies, and plies that break against the
Laminate Net Boundary.
Note:
Ply shapes that are closed and internal to the laminate Net boundary do
not need an Extended Ramp object.
MEMBER DESCRIPTION

Extended Ramp
Laminate The laminate used when ramping down extended boundaries.
Stagger Profile Defines the Stagger Profile, used when generating Extended Ramp
boundaries. The Stagger Profile determines the drop-off profile for
the plies that use the Extended Ramp.
Offset Offset Specifications tell Fibersim how to offset the curves that are
Specification being used to create the Extended Ramps.
First Boundary When an Extended Boundary has more than one domain, this
Ramp determines a boundary. The Extended Ramp is applied to this
boundary.
For parts with more than one domain, you need to create two
Extended Ramps. For example, if the part is a cylindrical section with
a boundary on each side of the cylinder, an Extended Ramp object
needs to be created for each side of the cylinder.
This option should be used to toggle between which of the laminate

curves will be used for the corresponding Extended Ramp object.
Match Step Whether plies linking to this ramp will get the same curve, if they
have the same step.
Geodesic Offset Whether to pull offset curves closer to the surface.

Curves

Minimum Course Extension
5.3 Minimum Course Extension
Minimum Course Extensions allow you to alter the non-tangent corners of ply shapes, to account for
minimum course restrictions imposed by using automated deposition machines.
You can select a ply and indicate next to the desired corner point. Fibersim then automatically creates
the minimum course extension.
MEMBER DESCRIPTION
Laminate Specify the laminate used for the Minimum Course Extension.
Determines which plies will be eligible for linking (under Ply).
Ply The ply that will have the Minimum Course Extension applied.
Note:
The plies’ orientation is used to orient the Minimum
Course Extension at the chosen non-tangency.

Minimum Specifies the type of Minimum Course Extension to be applied

Course Type at the chosen corner:
• Bird Beak
• Bat Ear
• Chamfer
Corner The non-tangent corner where the Minimum Course Extension

Point will be applied.
Note:
You should indicate a point next to the desired non-
tangent corner for the ply.
SPECIAL NOTE: In prior releases, the corner point used by an

MCE was simply stored as coordinates. Now, the corner point is
a physical CAD point created in the background and hidden.
This helps ensure that the MCE is not sensitive to the CAD part
being translated. The point is hidden as it is not intended to be
modified/changed.
• Any new MCEs that get created will have a CAD point
associated with them. If the MCE is deleted, the CAD point
will be deleted. If the point is changed through the MCE, it
will be replaced.
• Existing MCEs will not be affected unless they are modified

and changed, in which case they will upgrade to the new
behavior. Additionally, simply modifying an existing MCE
and clicking OK will trigger the upgrade.
Minimum Length value of the Minimum Course Extension.

Course
Length
The length should be entered in the CAD system’s current
display unit for length.
Extended Whether Fibersim will extend the Minimum Course Extension

Along Ply along the ply’s fiber direction.
Direction

Note:
Only valid when Minimum Course Type is set to “Bird
Beak.”

Minimum Course Extension Utility
5.4 Minimum Course Extension Utility
The Minimum Course Extension utility will allow you to automatically apply minimum course extensions
to plies. Each applicable corner of the ply will have a minimum course extension applied to it.
MEMBER DESCRIPTION
Minimum Course The type of Minimum Course Extension to be applied:

Type
• Bird Beak
• Bat Ear

• Chamfer
Extend Along Ply This option ensures that the minimum course extension
Direction extends along the ply’s fiber direction.
Add to Extended This option means that the minimum course extension
Ramps Only will only be applied to extended ramps.
ADD Machine You must select a default ADD machine from the ADD
machine database before running this utility.
Note:
Specify the ADD Machine on the Default ADD
Machine member on the Laminate object.
Minimum Course This value is the machine-specific minimum length for the
Length course extension. This member will populate once an AD
Machine is selected.
Minimum The minimum extension angle must be within the ply's

Extension Angle boundary.

Minimum Course Vertex
5.5 Minimum Course Vertex
Minimum Course Vertices allows you to alter non-tangent corners of layer shapes, to account for
minimum course restrictions imposed by using automated deposition machines.
Minimum Course Vertices are applied to Transition Adjacency Vertices. Fibersim applies Minimum
Course extensions to all necessary layers at the given Transition Adjacency Vertex.
MEMBER DESCRIPTION
Minimum Course The Minimum Course Extension applied to the chosen

Type corner:
• Bird Beak
• Bat Ear
Extend Along Whether to extend the Minimum Course Extension along

First Layer the layer’s fiber direction, or flip it 180× from the fiber
Orientation direction.
Note:
Valid when Minimum Course Type is set to “Bird
Beak”.

Minimum Course Vertex
See image below.
Alternate Alternates the direction of the extension, for each layer.

Extension
Direction Note:
Used when Minimum Course Type is set to “Bird
Beak.”

Minimum Course Vertex Utility
5.6 Minimum Course Vertex Utility
The Minimum Course Vertex utility will allow you to automatically apply minimum course vertices to
zone adjacency vertices.
Fibersim will also set the zone adjacency vertex’s Vertex Transition Method to “Minimum Course”, and
link it to the new MCV. The value of the Chamfer Length member will be the machine-specific minimum
length.
MEMBER DESCRIPTION
Laminate Select the parent laminate.
Minimum The type of minimum course vertex to be applied:

Course Type
• Bird Beak
• Bat Ear

Extend Along Whether to extend the Minimum Course Vertex along the
First Layer layer’s fiber direction, or flip it 180×.
Orientation
Note:
Valid when Minimum Course Type is set to “Bird
Beak”.
Alternate Alternates the direction of the extension, for each vertex.

Extension
Direction Note:
Only applicable when Minimum Course Type is set to
“Bird Beak.”
ADD Machine You must select a default ADD machine from the ADD
machine database before running this utility.
Note:
Specify the ADD Machine on the Default ADD
Machine member on the Laminate object.
Minimum This value is the machine-specific minimum length for the

Course Length course extension.
This member will populate once an ADD Machine is

selected.

Stagger Origin
5.7 Stagger Origin
The Stagger Origin utility is designed for use with Automated Deposition Machines. You can
automatically generate a set of staggered origins for a given set of plies.
In some Automated Deposition processes, you are required to stagger the origins for groups of plies of
similar orientations, and have material coverage areas in common.
Once a ply is linked to a Stagger Origin object the plies’ origin is overridden by the origin created by the
Stagger Origin object. When a single Stagger Origin object is used by multiple plies, choose a starting
origin that is inside of all the targeted plies.

Stagger Origin
MEMBER DESCRIPTION
Laminate The Stagger Origin object is defined on this parent laminate.

Fibersim uses the Laminate to determine the surface that
validates the point.
Origin Defines the starting origin point for the Stagger Origin object.
All offset origins will originate from this point.
Direction Defines whether origins will be offset based on the Fiber Axis
Type Direction or the rosette direction.
• Fiber Axis - Fibersim maps a chosen Fiber Axis curve to the

point chosen for the origin. This mapped vector direction is
then used as a direction for the offsetting of the additional
origins.
• Rosette - Fibersim uses the chosen rosette’s direction for

offsetting additional origins. You can use the same Stagger
Origin object for plies of differing orientations. Fibersim
creates staggered origins based on orientations of plies
that use the given Stagger Origin object.
Reverse This option will reverse the offset directions by 180 degrees.
Offset
Direction
Offset Type
Offset Type Whether the origin offset distance is based on:
• Material Width – Fibersim uses the Tow Width (specified

in the materials database) as a basis for offsetting
staggered origins. You must enter a Multiple of Width
value, which gets multiplied by the material’s width. This
will be the offset distance between each origin.
• Distance – Fibersim uses the Offset Distance value for the

spacing in between each staggered origin.
Material The material used, when Offset Type is set to “Material Width”.
Multiple of This factor is multiplied by the Tow Width of the material. This
Width value is then used as the offset spacing in between each
staggered origin.
Repeat Determines whether or not a “repeat after” will be used for

After offsetting stagger origins. For a default of 0, no repeat after is

Stagger Origin
used. For a value other than zero, Fibersim creates the specified
number of offset origins, and then starts the offsets over.
For example, if 4 is entered, Fibersim offsets 4 stagger origins,

and the 5th origin will start over at the base location.

Stagger Origin

6. Chapter 6: Documentation
6.1 Introduction
Fibersim’s documentation interfaces allows you to visually display laminate definition and
component information.
3D Cross Sections allow you to visually inspect the laminate stack, to ensure the desired design has been
achieved. Cross Sections are also useful in aiding manufacturing in the layup of the composite part.
You can also display core sample results, ply callouts and ply table information as 3D text annotations.
This lets designers display the laminate definition at a desired point in 3D.
3D Cross Sections and 3D Text Annotations can be used together to provide a visual and qualitative
representation of the composite definition.
Note:
To create 3D documentation, you must create annotation views and

annotation text in the model.

Planar Cross Section
6.2 Planar Cross Section
Planar Cross Section is a type of 3D Documentation that allows the user to select a plane in the CAD
system and generate a cross-section based on its intersection with the laminate surface.
NOTE #1: Offset Method – Nominal thickness
Note that all offset curves are created in the selected plane based on the nominal thickness of the plies
or layers. For planes that are not normal to the laminate surface, these offsets will not match the actual
thickness in the plane, but will produce more visually consistent results.
NOTE #2: Supported Part Types
At this time, Planar Cross Sections do not support laminates containing core or child laminates
withdifferent layup surfaces. Wrapped plies and fully closed loops are also not supported.

Creating a Planar Cross Section
By default, the cross section will cross the entire laminate. If the user wishes to shorten the cross
sectionsegment they can use the Trim Start and Trim End fields which will trim back from either end of
thebase curve. If the selected plane intersects the laminate surface at multiple segments, the user can
use the Next Curve Segment to pick which segment is meant to be shown.
As with the 3D Cross Section, the user can choose between Net and Extended boundary type, Ply or
Layer, and define the scale of the offset curves. There is also the option to generate CAD geometry.
There is also the ability to change the Ramp Ratio. By default this is set to “1” and follows the drop-off
ofply/layer shapes very closely. Raising the value (maximum of 20) causes the ramps to smoothen out
and provide a more visually pleasing result.
The base curve that gets created from the planar intersection is shown below in green, with the user-
selected plane in pink. The yellow curve denotes the start and direction of the cross section.

In the image below you can see a comparison of the default ramp ratio of “1” and using a higher
rampratio of “7”.


3D Cross Section
6.3 3D Cross Section
In the design of a composite part, you may want to see the cross section of the laminate in 3D space, on
the tool surfaces. This helps visualize how plies and cores will be laid up on a tool surface.
Note:
All values in the materials database are listed in the Index: Materials &
Machine Database, section A.3.
The Cross Section tool colors cross section curves based on ply orientations for each material. You can
optimize the line color, line style and line thickness. Boundary styling is specified for each material used
in the materials database.
The default styling scheme based on the materials database is summarized here:
Ply Orientation Curve Color Line Type Line Thickness
0 Blue Solid Thin
90 Yellow Solid Thin
45 Green Solid Thin
-45 Red Solid Thin
135 Red Solid Thin
Non-Standard * White Solid Thin
* Non-Standard refers to user-input angles that are not specified above. For example, if you enter 30 for
the specified orientation, the cross section curve that corresponds to this ply will be colored white. Core
objects will also be white in generated cross sections.

3D Cross Section
MEMBER DESCRIPTION
Laminate The laminate on which the cross section will be performed.
Cross Section Curves that determine where on the tool surface the cross section
Curve will be created. The curve must be on the chosen Laminate and can
be a curve, line, or spline.
Offset Type Determines how distances between plies in the cross section display:
• Scaled – distance between plies, relative to the material

thickness of each individual ply. Ply Offset Scale and Core
Offset Scale generate the cross section. Ply and core material
thickness are multiplied by their values to determine each
individual offset.
• Constant – Ply Offset Value and Core Offset Value determine

the offset for each individual ply and core.
Component Type Fibersim generates the cross section based on a ply or a layer.

3D Cross Section
Boundary Type Whether the cross section will be propagated to ply net boundaries
or extended boundaries.
Style Specifies the style of the cross section.
• A Draped cross section displays a profile with Ply ramps, due to

material draping and part curvature.
• A Schematic cross section displays a profile of constant

thickness with part curvature.
• An Over Core Hybrid cross section behaves like a Draped cross

section under the core, and a Schematic cross section over it.
Profile Type How to display each ply, either a line or a rectangle.
Minimum For draped cross sections, this member specifies the minimum
Distance allowable distance between two separate ramps of a ply profile.
Between Ramps
If the distance between two ramps is below this value, Fibersim will
“smooth” the ply profile into one ramp. This value must be greater or
equal to 0, and is in units of the model.
See the image below.
Cross Section Specify a user-specific offset for the cross section. This option allows
Offset you to move the cross section to a more visible location.
Generate Generates the 3D cross section. If changes are made, perhaps by

creating new plies, use this to re-generate the cross section and
update it with design changes.
Create Cross Section Geometry
Fibersim creates cross section as display geometry (No) or as actual CAD geometry (Yes).
Output Curve Creates output curves as construction output curves (resulting Ply
Type boundaries are output as splines), or result output curves (chainable
curves).
Geometry Locked When set, the cross section geometry cannot be updated.

Definition of Minimum Distance Between Ramps
6.3.1 Definition of Minimum Distance Between Ramps
Notice how the cross section has two different distances between ramps:
• Top distance is 0.20 inches
• Bottom distance is 0.40 inches
This illustrates how the minimum distance between ramps influences how cross sections drape over Ply
drop-offs.
If you input a value for the minimum distance between ramps below the lowest distance then Fibersim
will drape cross section plies over every ramp (Case 1).
But, in Case 2, if you enter 0.30 inches, then Fibersim will drape over the 0.40 distance and smooth over
the 0.20 distance.
Fibersim will treat each distance between ramps as a case for smoothing. Ramp distances are not added
up to meet or exceed the minimum distance between ramps.

Explode Laminate
6.4 Explode Laminate
The Explode Laminate tool creates a visual representation of the ply stack-up, on a selected laminate.
This tool explodes each ply, at a specified distance from each other.
MEMBER DESCRIPTION
Append When enabled, Fibersim will append the plies' sequence/step

Sequence/Step to the CAD geometry name.
to Geometry
Name
Boundary Specifies which boundary exploded plies will be based on:

Type
• Net – explode plies using Net Boundaries
• Extended – explode plies using Extended Boundaries

Explode Laminate
Offset Type Whether the offsets will Constant or Scaled:
• Constant – Plies exploded at a distance from each other

specified by the Ply Offset Value.
• Scaled – distance based on multiplying the cured

thickness of ply material, by the Ply Offset Scale value.
Ply Offset Distance between each exploded ply. The distance is the
Scale result of multiplying the cured thickness of the chosen
material and the value entered here.
Note:
When Offset Type is set to “Scaled”.
Core Offset Distance at which the plies are exploded off the core.
Scale Distance is the result of multiplying the cured thickness of
the chosen material and the value entered for this member.
Note:
When Offset Type is set to “Scaled”.

Flat Pattern Layout
6.5 Flat Pattern Layout
This utility allows you to manipulate how flat patterns display in the CAD window. By setting the
parameters, such as cell width/height values and origin coordinates, you can ensure that the flat
patterns properly display in the CAD window in a grid fashion.
MEMBER DESCRIPTION
Laminate Laminate that contains the plies’ patterns you want to

manipulate.
Plies Select the plies from the laminate, whose patterns you
want to manipulate.
Boundary Type Rearranges either the Net or Extended patterns of the

selected plies.

Flat Pattern Layout
Grid Origin (X & Y) The X & Y coordinate values that determine the location
of the first cell in the grid.
Cell Width Width value for the cells in the grid.
Cell Height Height value for the cells in the grid.
Spliced Ply The space between spliced plies in a grid cell.

Spacing
Row Direction Select the axis to use to orient the row direction.
Column Direction Select the axis to use to orient the column direction.
Cells per Row Number of cells per row to have in the grid.

3D Text Annotations
6.6 3D Text Annotations
6.6.1 Core Sample
Core Sample annotations allow you to display design station results in a 3D text object. These 3D text
objects are text with or without leaders that Fibersim uses to populate with design station results. Core
Sample annotations are driven by Design Stations.
Note:
When a design station that is associated to a core sample annotation is

updated, the text associated to the annotation will also be updated.

Core Sample
MEMBER DESCRIPTION
Design Station The design station determines which plies get displayed in
the annotation based on core sample results. (When a
design station is updated, the annotation is too.)
Annotation When this option is checked, the annotation text will not
Locked change, even if the status is out-of-date.
Annotation Text leader in which to display this annotation.

Leader
Summary Summary information that is displayed in the core sample.

Information Count is the total ply count at the core sample origin.
Thickness is the total laminate thickness at the core sample
origin. Options are:
• Count / Thickness
• Count
• Thickness
• Name / Thickness / Percentage
• None
Component Component information that is displayed in the core

Information sample:
• Ply name
• Sequence/step
• Orientation
• Material
• Thickness
Header Text Any notes to be displayed on the header of this document.
Column Separation character, to separate columns of information

Separator in the annotation.
Lines Per Maximum number of lines per column in the annotation.

Column

Core Sample
Reverse Reverses the order in which components are listed.

Sequence

Ply Table
6.6.2 Ply Table
Ply Table Annotations allow you to display ply and core information in a 3D text annotation. The
annotation will display all ply and core objects defined on a laminate.
NOTE: The annotation will update automatically when ply information is

altered.
MEMBER DESCRIPTION
Laminate The laminate to decide which ply and core objects will display.
Note:
Choosing a top-level laminate means all ply and core
objects in the composite part are displayed.

Ply Table
Annotation Defines the text leader in which to display this information.

Leader
Column The character used to separate the columns of ply

Separator information in the annotation.
Lines Per Column - Maximum number of lines per column in

the annotation.
Reverse Sequence - Whether Fibersim will invert the ply

order (Yes) that is displayed in the annotation, or not (No).
Include Net Area - Include the net area values in the ply
table.
Include Extended Area - Include the extended area values in

the ply table.
Text Lines Optional lines of text that can be inserted into the ply table.
Line Indices Zero-based index that specifies the location of the text lines in
the ply table.

Ply Callout
6.6.3 Ply Callout
Ply Callouts will display all ply and core objects, defined on a laminate at a specified point. If the point is
not on a piece of curve geometry, Fibersim will find the closest curve, and list the ply and core objects
that use this curve.
MEMBER DESCRIPTION
Laminate The laminate that decides which ply and core objects get
displayed.
Note:
For a top-level laminate, all plies and cores in the
composite part are displayed. But if a child laminate is
selected, only plies and cores of that laminate (and its
children) display.

Ply Callout
Boundary Type Whether the callout will search for Net or Extended
boundaries.
Callout Point The location used to gather ply and core information.
Annotation Text leader in which to display this annotation.

Leader
Prefix Additional text to display before the callout. Any valid text
string can be used for the prefix.
Number of Defines how many ply or core objects display on each line
Names Per Line of the callout. Values are any valid integer.
Default value is 10 names per line.

Material Table
6.6.4 Material Table
This object lets you create a table of materials used in the plies and laminates.
Note also that additional non-modeled materials may be added manually and retained
during updates.
MEMBER DESCRIPTION
Laminate References the parent laminate.
Annotation Leader Text leader, in which to display this annotation.
Non-Modeled List of non-modeled materials. You can manually select

Materials materials to be added to the table.
Column Separator The symbol to use as the column separator.

2D Drawings (CATIA V5 and NX Only)
6.7 2D Drawings (CATIA V5 and NX Only)
2D Drawings provide a method of transferring 3D information into a 2D document. This information can
then be passed on to manufacturing in either electronic or printed format.
Note:
All values in the materials database are listed in the Index: Materials &
Machine Database, section A.3.
The 2D documentation tool colors ply and core curves, based on ply orientations for each material. You
can optimize the line color, line style and line thickness for generated 2D curves.
Boundary styling is also specified, for each material used in the materials database. You can customize
the line color, line type, and line thickness for each material and orientation.
The default styling scheme (based on the materials database) is summarized here:
Ply Orientation Curve Color Line Type Line Thickness
0 Blue Solid Thin
90 Yellow Solid Thin
45 Green Solid Thin
-45 Red Solid Thin
135 Red Solid Thin
Non-Standard* White Solid Thin
* Non-Standard refers to user-input angles that are not specified above. For example, if 30 is input for
the specified orientation, the 2D curves that correspond to this ply will be colored white. (Core objects
are considered non-standard, so they will be colored white.)

Ply Book
6.7.1 Ply Book
Ply Books are intended as a way of sharing drawings in a book. Information such as step, sequence,
material names, etc. can be listed in a text block while 2D/3D (isometric, front, etc.) views can be shown
with an overlay of each ply. Each sheet in the book may contain a view of the tool geometry with a 3D
ply boundary, as well as the flat pattern shape for each ply.
Note:
Flat Patterns need to be created in order to be viewed in the ply book
CREO PARAMETRICS NOTE: Template sheets can only be selected by picking a

draft entity such as a view, table or note. At this time, sheet names in Creo
Parametrics cannot be programmatically controlled by Fibersim.
You must first open (or create a new) Template Sheet and create an Isometric view. Make sure both the
model and the template sheet are open in CAD. Then, from the CAD window:
1. Click Insert > View > Projections > Isometric.
2. Click the model to create the link to the template sheet.

Ply Book
Showing a Ply Book template sheet

Ply Book
Workflow
1. Link to the pre-existing Template Sheet.
2. Select a laminate. Only one laminate per ply book is allowed.
3. Specify which plies (Source Objects) used to generate the ply book sheets.
4. Generate/update the ply book sheets.
5. Press Remove Generated Sheets to remove unnecessary or outdated sheets.
MEMBER DESCRIPTION
Name The name will be at the beginning of the name of

each tabbed view in the drawing, followed by the ply
name.
Laminate Only one laminate per ply book is allowed. Note also
that only plies for that laminate are available (plies
of child laminates do not show up.)

Ply Book
Status Ply Books are either “Out-of-date” or “Up-to-date”,

whether updated since the last change to the
composite data.
Source Objects Specifies which plies will be used to generate sheets

of the book.
Template Sheet Link to the pre-existing template sheet, with all the
necessary text and diagram objects.
Generate/Update Sheets Generates/updates the ply book sheets.
Remove Generated Sheets Removes the generated sheets.
Options
Starting Page Number Specify the page number at which to start the ply
book.
Allow out-of-date patterns Allow out-of-date patterns in the ply book.
Shade Components
Since certain parts have complex shapes and assembly processes, this option will shade
the internal area of any selected plies and/or cores. This option affects all generated views
for a single plybook object.
The surface on the boundary view will be colored based on the material’s orientation color
(similar to the boundary curves). If Fibersim fails to create the split surface for any
component, an error will be presented at the end of Ply Book generation.
The Laminate Color and Laminate Transparency members will apply to the laminate
surface as shown in the boundary view. Setting the laminate color to the same as the
sheet background in addition to applying some transparency to it will aid in visualization of
shaded surfaces.
NOTE: All shown surfaces in the CATPart may be seen in the boundary view. It is
recommended to hide all surfaces except for the Laminate surface prior to generation.

Ply Book
Text Setup Tab & Diagram Setup
Text Setup - Text Associations
Here you can set up Ply Book text associations. You can populate text fields on the drawing
to clearly identify the ply name, sequence, material and a variety of other attributes.
1. Right-click and Create New.
2. Select existing template text (Text Link). Text will display in the “Current Text” column.
3. Specify the object type being reported (Source Member).
Text Association columns include:
Text Link Define text associations by selecting existing

template text.
Current Link Displays the current text in the “Text Link”

object.
Source Member The object type being reported.
Text Setup - Table Associations
Here you can set up the Ply Book table associations. You can populate text fields to identify
the table columns.
1. Right-click and select Create New.
2. Select an existing table on the template sheet. (Table Link).
3. Define the table’s columns.
4. Check options to preserve the table’s title or read the title by row.
Table Association columns include:
Table Link Define table associations by selecting existing.
Define Columns Define the table’s columns.
Preserve Title Check to preserve the table’s title.

Ply Book
Read Title By Row Check to read the title by row.
Diagram Setup
This is a display of ply book table associations.
Select how to break out the ply book, either by Sequence-Step or Component.
Boundary Type - Specify either the Net or Extended boundary.
You can also right-click to create either a boundary diagram or a flat pattern diagram.
Display Layup Information – Displays the propagation method and direction in the ply
book.
Break on Sequence-Step: Break on Component:
Use Flat Pattern Layout - Uses the flat

pattern layout utility.
Include Origin and Direction - displays the Include Origin and Direction - displays
ply direction in the flat pattern diagram. the ply direction in the boundary diagram.

Ply Book Surface
6.7.2 Ply Book Surface
When a ply book is generated, split skins are created for each selected component and stored in the
part. If the component shares the same boundary as the laminate, it will inherit a copy of the laminate's
surface.
The split skins are managed by Source Object Details, shown in the on-form table on the bottom of the
“Generation” tab on the Ply Book object. Each Source Object Detail is linked to a Ply Book Surface which
stores the link to the surface in the part.
A Ply Book Surface object is created for each component in the Ply Book. They are managed by the Ply
Book and cannot be created or deleted by the user. The Ply Book takes care of deleting unused Ply Book
Surfaces (and linked geometry) as needed.

Ply Table
6.7.3 Ply Table
Ply Tables contain pertinent part information displayed in a table format. A ply table can include
document entities such as Ply Name, Step, Orientation, Material, etc. You have complete control over
the style of template and precisely how many columns you wish to generate.
CREO PARAMETRICS NOTE: Template sheets can only be selected by picking a

draft entity such as a view, table or note. At this time, sheet names in Creo
Parametrics cannot be programmatically controlled by Fibersim.
You must first open the Template Sheet and create an Isometric view. Make sure both the model and the
template sheet are both open in CAD. Then, from the CAD window:
1. Click Insert > View > Projections > Isometric.
2. Click the model to set the link to the template sheet.

Ply Table
Workflow
1. Select a pre-existing Template Sheet.
2. Select the laminate, which will specify which plies will be available for this table.
3. Select the plies (Source Objects) that will be used to generate the table rows.
4. Press Generate/update to create the table.
5. Press Remove Generated Sheets to remove any unnecessary or outdated sheets.
Table Setup
MEMBER DESCRIPTION
Laminate Specifies which plies will be available for this table.
Only one laminate per table object is allowed. Only plies for this
laminate are available (any plies of child laminates do not appear.)
Status The table is either Out-of-date or Up-to-date, depending on whether it

has been Generated/Updated since the last change.
Source Objects Plies used to generate the table rows.
Template Sheet A pre-existing template sheet with all necessary text.
Generate/ Generate/update sheets.

Update
Remove Remove certain generated sheets.
Defining Text Associations
Items Per Page - how many rows of ply information will appear on each Ply Table sheet.
2. Set the Text Link to the table being populated.

Ply Table
3. Specify the object type being reported (Source Member).
Columns of information include:
Text Link Define text associations by selecting existing template text.
Current Text Displays the current text in the “Text Link” object.
Source Member The object type being reported.
Defining Table Associations
2. Define the columns that will display in the table.
3. Check the options to preserve (display) the table title, or to read the title by row.
Columns of information include:
Table Link Current table being populated.
Define Columns Columns that will display in the table.
Preserve Title Whether or not to preserve (display) the table title.
Read Title By Row Read title by row (Yes or No).

Ply Table

Ply Table

7. Chapter 7: Parametric Surface Offset
(PSO) Elements
7.1 Introduction
The PSO section on the application browser contains these objects, which will be populated with data
once the PSO utility is run:
• PSO Surface
• PSO Constant Area
• PSO Ramp Area
• PSO Constant Rail
• PSO Ramp Rail
SPECIAL NOTE #1: You can manually create a PSO Surface (though this is not usually
recommended), but you cannot manually create any of the other PSO objects. These will
only be created when the PSO utility is run. However, these objects are editable for the
purpose of specific geometry overrides.
SPECIAL NOTE #2: The PSO utility is described in Index B: Fibersim Utilities, section B.6.1.

Parametric Surface Offset utility
7.2 Parametric Surface Offset utility
Note:
This utility is discussed in detail in Index B, section B.6.

Parametric Surface Offset (PSO) Surface
7.3 Parametric Surface Offset (PSO) Surface
The PSO surface (created when the PSO utility is run) serves as a parent for all of the ramps and areas.
The PSO Surface data structure manages the results generated for a given PSO run. If the user makes
any design changes that change layer shapes or part thicknesses, then the PSO utility needs to be re-run.
Running an update on the PSO surface object only affects the current objects in the data structure. It is
only necessary to run a PSO surface update if, for any reason, the user needs to override geometry
created by Fibersim.
MEMBER DESCRIPTION

Parametric Surface Offset (PSO) Surface
Laminates This identifies the laminate from which the PSO surface was created.
Ramp This field determines the type of surface to use for the ramps:
Generation
• Swept - Fibersim creates a multi-section surface (on V5) or a
swept (on NX). If this fails, Fibersim creates a fill surface (on V5)
or an n-sided surface (on NX). Note that lofts fail when not 4-
sided with two sections and two guides.
• Fill - Fibersim will create a fill surface (on V5) or n-sided surface
(on NX).
Update Method Determines the strategy for replacing geometry when a PSO is run.
Last Component Last component in the laminate to offset.
Create Solid to Create Solid to Net Create a solid to the net boundary of the
Net laminate.
Crossing Layers Compute constant gage areas by interseting all layers in each layer
shape.
Minus-One Trims back constant gage surfaces by one offset distance

Offset
Joined Surface Generates a joined surface.
Overwrite Ensures that thickness values are overwritten each time a Generate is
Thickness performed.
Values
Generate Generates or updates the PSO surface, and the IML geometry.
Note:
Running this update only has an effect when the user has
overridden geometry in the PSO data structure. Changes to the
part design make it necessary to run an update of the PSO
utility. (Part design changes are anything that changes the layer
shapes or part thickness.)

PSO Constant Area
7.4 PSO Constant Area
Constant areas represent the constant thickness regions of the part being designed. These areas will be
created when the PSO utility is run and the offset distance (thickness) is driven from a CAD parameter.
MEMBER DESCRIPTION
IML Surface This identifies the current IML surface that represents the offset constant
Feature surface.
Thickness Thickness value of the area's offset thickness. This value can be changed,
however this is not recommended as a design change. This should only
be used in the event Fibersim computes the wrong thickness for a given
region.
PSO Surface This identifies the current parent PSO surface.
IML Surface This field lets you select a different surface, to override the generated
Override IML Surface. This should be used for cases where the Fibersim-generated
surface has an unwanted anomaly (wavy region, hook surface, etc.)

PSO Constant Area
This should not be used to change the entire shape of a constant area.
This will create errors when updating the PSO surface, since the overall
topology has changed.
Note:
If you do select an override surface, you will have to re-generate
the PSO surface.
IML Status This displays the status of the IML geometry of the child objects, as either
up-to-date or out-of-date.
When an override is made this status will go out-of-date. Upon updating

the PSO surface this status will be up-to-date.
Rails This is a list of all of the current constant rails.

PSO Ramp Area
7.5 PSO Ramp Area
These are the areas of the surface that form a ramp. These areas are created when the PSO utility is run
(with the "Ramp Generation" option checked).
MEMBER DESCRIPTION
IML Surface This identifies the current IML surface.

Feature
PSO Surface This identifies the parent PSO surface.
IML Surface This field lets you select a different IML surface, to override the
Override generated one. This should be used in cases where the Fibersim-
generated ramp is undesired.
Since Fibersim creates a CAD feature for the ramp, in most cases the
CAD feature can be manipulated to get the desired result. This should be
the first action tried before completely overriding the ramp.
NOTE: If you do select an override surface, you will have to re-generate

the PSO surface.

PSO Ramp Area
IML Status This displays the status of the IML geometry of the child objects, as
either up-to-date or out-of-date.
Rails This is a list of all of the current ramp rails associated with this area.

PSO Constant Rail
7.6 PSO Constant Rail
Constant rails represent the edges of the constant areas. The constant rails are also used to bound the
ramp edges that run along the thicker and thinner constant areas.
MEMBER DESCRIPTION
OML Curve This identifies the current OML curve. (This can be a curve or a
chain of curves.) This curve represents the lowest level
building block for the PSO data structure.
This curve is created on the laminate surface and is driven

from Fibersim's composite definition.
IML Curve This identifies the current IML curve. (This can be a curve or a
chain of curves.) The IML constant curves are driven from the
IML surface edges.
Area 1 This identifies the constant area associated with the given
constant rail. (This is read-only.)
Next Rail 1 The connected rail that continues counter-clockwise around

Area 1. (This is read-only.)

PSO Constant Rail
Thickness Thickness value of the rail.
PSO Surface This identifies the current parent PSO surface.
OML Curve This field lets you select a different OML curve, to override the
Override current one.
When possible, users should override the OML rail and let
Fibersim compute the IML rail.
NOTE: If you do select an override curve, you will have to re-

generate the PSO surface.
IML Curve This field lets you select a different IML curve, to override the
Override current one.

Area 2 This identifies one of the areas on either side of the rail. (This
is read-only.)

IML Status This displays the status of the IML geometry of the child
objects, as either up-to-date or out-of-date.
This status goes out-of-date when either an OML or IML

override has been made. In this case, running a PSO surface
update is necessary to bring the status back to up-to-date.

PSO Ramp Rail
7.7 PSO Ramp Rail
Ramp rails contain different thickness values at each end of the rail. These areas are created when the
PSO utility is run (with the “Ramp Generation” option checked). Ramp rails represent the connection
between the constant areas.
MEMBER DESCRIPTION
OML Curve This identifies the current OML curve. (This can be a curve or a
chain of curves.)
This curve represents the second lowest level building block

for the PSO data structure. This curve is created on the
laminate surface and creates connections between the
constant areas.
IML Curve This identifies the current IML curve. (This can be a curve or a
chain of curves.)

PSO Ramp Rail
The IML ramp rail curves are computed by sweeping the OML
ramp rail by the appropriate thickness.
is read-only.)

Thickness 1 The thickness of the rail where this rail meets Next Rail 1. (This
is read-only.)
PSO Surface This identifies the parent PSO surface.
OML Curve This field lets you select a different OML curve, to override the
Override generated one.

IML Curve This field lets you select a different IML curve, to override the
Override generated one.

is read-only.)

Thickness 2 The thickness of the rail where this rail meets Next Rail 2.
IML Status This displays the status of the IML geometry of the child
objects, as either up-to-date or out-of-date.

PSO Ramp Rail
The IML status goes out-of-date when either an OML or IML

override has been made. In this case, running a PSO surface
update is necessary to bring the status back up-to-date.

PSO Ramp Rail

8. Chapter 8: Import/Export
8.1 Introduction
Fibersim’s special interfaces allow you to import data into Fibersim and export data out to special
formats and cutting machines. You can work with flat pattern data, Laser Projections and Automated
Tape Laying data.
On the main toolbar, under File there are two sections, Import and Export. This chapter will show all of
the options for each, as well as showing the user interfaces for each object.
SPECIAL NOTE: Each of the Interfaces is sold and licensed individually.

Import Options
8.2 Import Options
Each of the following interfaces allows you to import ply analysis data into Fibersim.
8.2.1 Analysis – Ply

Analysis – Ply
MEMBER DESCRIPTION
Components Specify the components to be exported.
Boundary Type Specify export of Net or Extended boundaries.
Coordinate System Analysis data is written relative to this coordinate system.
Allow Offset Simulation Check this option to use the offset simulation value (set
from the Ply “simulation options” menu).
Use Mapped Exports rosette-mapped orientation directions without

Orientations running a simulation.
Use Base Boundary Trims the output mesh back to the “nominal” boundary,
removing applied zone transitions.
Use Manufactured Part This will remove cutouts from the final result.
Include non-Structural Include non-structural materials in the export.

Materials
Export Rosettes as a This lets you export field-based rosettes to HDF5 and CP
Field XML. If the rosette is currently a non-field-based rosette, it
will be exported as a field-based one.
This is a list of the interface options, all for exporting ply analysis data:
INTERFACE DESCRIPTION
Altair Fibersim data can be exported to Altair Hyperworks.

Hyperworks
Ansys ACP With this new export interface, fiber compression information can be
transferred from Fibersim into Ansys.
Beta CAE Ansa This is an export object to the CAE ANSA tool, with zone support.
HDF5

Analysis – Ply
Beta CAE Ansa This is an export object to the CAE ANSA tool.
CAE Exchange For large parts, Fibersim now makes it easier when exporting analysis
Format data for all plies at once. You can export multiple HDF5 files, consisting
of subsections of the plies of the parts, and then merge these files so
that one HDF5 file contains all of the plies.
CATIA Analysis Select the Laminate Surface and Update Parameter.
MSC Laminate The MSC Analysis Interface file format is compatible with PATRAN/
Modeler Laminate Modeler from the MacNeal-Schwendler Corporation (MSC). It
performs finite element analysis of composite structures. Two types of
analysis files are created:
• The master file contains filenames of each ply layup file for which
analysis data was generated. The file has the extension .fmd
(Fibersim-MSC Directory file), and is named from the Base File
Name parameter (e.g., LAM001.fmd.) The file contains a list of
analysis interface output files that were generated for the part, in
the sequence they were exported.
• This Ply Layup File contains analysis data for each individual ply.
Files use the extension .fml and are named from the Base File
Name parameter and the ply name, e.g., LAM001-P001.fml.
(Fibersim-MSC Layup File)
MSC Layup This interface writes CAE data in the .layup format.
MSC Patran Patran is a widely used pre/post-processing software for Finite Element
Analysis (FEA), providing solid modeling, meshing, and analysis setup.
Patran provides a rich set of tools that streamline the creation of
analysis ready models for linear, nonlinear, explicit dynamics, thermal,
and other finite element solvers.
From geometry cleanup tools that make it easy for engineers to deal
with gaps and slivers in CAD, to solid modeling tools that enable
creation of models from scratch, Patran makes it easy for anyone to
create FE models.

Analysis – Ply
MSC SimXpert Because Fibersim is completely integrated into commercial 3D CAD

systems, the Fibersim composite definition and SimXpert's FEA
definition are linked directly to the same CAD geometry.
This allows products to be designed, validated, and optimized without

having to translate volumes of data between different software tools.
NX Laminate For exporting NX Laminate Composite data.

Composites
PAM-RTM The PAM-RTM Analysis Interface file format is compatible with PAM-
RTM from ESI GROUP. This tool simulates the manufacture of composite
parts via the resin transfer molding process.
A single file is generated for all selected plies, containing orientation

data for each ply. The data has the same coverage as the plies in the
CAD model, and allows orientation information to be supplied to each
element of the mesh generated by the analysis software.
Generic BDF formats allow you to export the results of a detailed core sample
Format BDF for a given point. The point used to obtain the data is specified in the
target Design Stations, that represent areas of constant thickness, and
then the laminate stack-up at the Design Stations origin location can be
exported into BDF format.
When exported, a single file (xx.bdf) lists all plies for which analysis
data has been created. This file also contains Layup information,
including XYZ locations of each node, as well as warp and weft fiber
angles.
Generic The XML format is used to transfer fiber orientation data to various
Format XML analysis packages. XML data can be converted to any other data format
using XSL transformations, allowing for seamless integration with
virtually any application capable of importing data. Since XML is so
flexible, XML Analysis Interface files can be converted into various
customized file formats for use with commercial or proprietary software
packages.

Ansys ACP
8.2.1.1 Ansys ACP
With this interface, you can import data into Fibersim to create (or update) plies and layers from the CAE
system. The interface allows you to map CAE Material names to the proper Fibersim materials. You can
also get the boundaries of the components in the CAE data and use that as geometry in the CAD system,
by creating curves-on-surface from the CAE data.
This interface will also handle updates from the CAE. Once changes are made, the data can be re-
imported and the changes viewed.
MEMBER DESCRIPTION
Analysis Exchange This is the CAE file to be reviewed and imported. The file must be
File an HDF5 file format.

Ansys ACP
When you select the file and press View Analysis File, the file
contents will display in the window and a message will confirm
what was loaded.
File Creator This will display the creator of the HDF5 file.
Import Reference This is the reference coordinate system that will be applied to the
Transform imported data.
Last Modified Date This is the last modified date of the HDF5 file.
Import Options
Interpret Data As This option controls whether plies or layers will be imported. This
also controls whether plies or layers will be used for matching
incoming data with existing data.
Import Boundary Select either Net or Extended boundary.

Type

Ansys ACP
Material Mapping
This window will display the list of materials from the HDF5 file, with the mapped materials from
Fibersim. Here you can change the Fibersim material that you would like assigned to a given Analysis
material. Upon importing, Fibersim will assign the materials based on the chosen material mapping.

Ansys ACP
Analysis Rosettes
When an HDF5 file is viewed, a series of temporary rosettes is created. You can assign
permanent objects to each rosette. The temporary Fibersim components will link to these temporary
rosettes. You can create Fibersim rosettes from the analysis rosettes, or you can choose to associate a
given analysis rosette to an existing Fibersim rosette.
When you double-click on a rosette, the "Modify Rosette" window will open:
• You have the option to create a permanent rosette from the temporary version (using the Create
New Rosette button). If a permanent rosette is created from the temporary one, the temporary
rosette's permanent link will be filled in as the new rosette.
• Or, you can elect to update the link to a permanent rosette (by selecting a rosette from the
Fibersim Rosette drop-down menu).

Ansys ACP
Component Review window (contents from the HDF5 file)
When a file is viewed, a series of display components (plies or layers) are created. These objects are
representations of what is in the HDF5 file, and allow linking to the permanent Fibersim objects.
Or, if no objects exist as a match, then these CAE representations can be imported as new plies. Existing
Fibersim components that do not match any of the components in the CAE file will be shown in the
"Analysis name" column as <Not in File>.

Beta CAE ANSA
8.2.1.2 Beta CAE ANSA
With this interface, you can import data into Fibersim to create (or update) plies and layers from the CAE
system. The interface allows you to map CAE Material names to the proper Fibersim materials. You can
also get the boundaries of the components in the CAE data and use that as geometry in the CAD system,
by creating curves-on-surface from the CAE data.
This interface will also handle updates from the CAE. Once changes are made, the data can be re-
imported and the changes viewed.
SPECIAL NOTE: The Material Mapping, Analysis Rosettes and Analysis Components
windows work the same way as described in the “Ansys ACP” section (10.2.1).
MEMBER DESCRIPTION

Beta CAE ANSA
When you select the file and press View Analysis File, the file
contents will display in the window and a message will confirm
what was loaded.
Coordinate System This is the reference coordinate system that will be applied to the
imported data.
Interpret Data As This option controls whether plies or layers will be imported. This
also controls whether plies or layers will be used for matching

Type

CAE Exchange Format (Ply Import)
8.2.1.3 CAE Exchange Format (Ply Import)
This object allows you to view data in an HDF5 file before any permanent Fibersim objects are created.
This import will display a list of objects in the file from which Fibersim objects can be created.
You can assign laminates, materials and rosettes to the temporary objects, which will be assigned to the
new components upon creation. You can also link the temporary object to a permanent Fibersim object,
and provide the option to update the permanent object based on the temporary one. This interface also
allows you to refine CAE boundaries, before importing and assigning them to Fibersim ply\layer objects.
Note:
If any data already exists, links will be preserved where possible.
SPECIAL NOTE: The Material Mapping, Analysis Rosettes and Analysis

Components windows work the same way as described in the “Ansys ACP”
section (10.2.1).

CAE Exchange Format (Ply Import)
MEMBER DESCRIPTION
When you select the input file and press View Analysis File, the file
contents will display in the “Component Review” list and a
message will confirm what was loaded.
Coordinate System This is the reference coordinate system that will be applied to the
imported data.
Interpret Data As Set this option to control whether plies or layers will be imported.
This also controls whether plies or layers will be used for matching

Type

CAE Import to Overlay Zones
8.2.1.4 CAE Import to Overlay Zones
The CAE import object will allow you to import overlay zones from CAE data. This object lets you preview
the contents of the CAE file before creating or updating any Fibersim objects. You can identify the
different, perhaps intersecting, overlay zones contained in the CAE file.
You can then match overlay zones contained in the CAE file with already existing overlay zone objects.
This allows you to see the difference between the two sets of overlay zones.
• If any data is already grouped into zones, Fibersim will group any new analysis components with
the same name into the same zones if possible.
• If zones are missing any of their components, there will be a notifying message.
• If an analysis overlay zone is missing all of its components that overlay zone will be deleted and the
user is notified. Any previously-imported Fibersim overlay zones will not be deleted. Overlay zones
can only be deleted outside of the import object.
• The highlighting context for overlay zones will highlight all of the analysis components that the
zone contains. This a quick way to tell if any component geometry of the zone has changed (but
keeps the same name).

section (10.2.1).

CAE Import to Overlay Zones

MSC Laminate Modeler Import
8.2.1.5 MSC Laminate Modeler Import
This object provides the ability to import an MSC Laminate Modeler Lay-up File.

MSC Laminate Modeler Import
MEMBER DESCRIPTION
Import File Name of the Laminate Modeler file, read into Fibersim.
Specified Objects
Laminate This laminate serves as the parent of all imported plies and
rosettes.
Material The material to use for the imported components.
Curve Type Specifies the type of curve (construction or result) to be created

for imported boundaries or holes.
Boundary Type The component boundary type, either Net or Extended.
Add Surface This option means that the laminate surface will be used as a
Support support for the created curves.
File Units Specifies the units to display in the imported file.
Non-tangency Defines the angle, that defines the non-tangency for splines.
Angle
Sequence Imported components will belong to this sequence. (Corresponds

to the selected laminate.)
Starting Step Step value at which imported components will start.
Step Increment Number by which imported components’ step values will

increment.

NX Laminate Composites
8.2.1.6 NX Laminate Composites
This object lets you import a file that contains NX laminate composite data.

section (10.2.1).
MEMBER DESCRIPTION

NX Laminate Composites
When you select the input file and press View Analysis File, the file
contents will display in the “Component Review” list and a message
will confirm what was loaded.
Import Reference This is the reference coordinate system that will be applied to the
Transform imported data.
Interpret Data As Set this option to control whether plies or layers will be imported.
This also controls whether plies or layers will be used for matching

Type

Analysis - Zone
8.2.2 Analysis - Zone
The interface options under this section, are all for exporting zone analysis data:
MEMBER DESCRIPTION
Zones Specify the zones to be exported.

Analysis - Zone
Output Units Select the units for the output.
Directory Directory where the output file will be located.
File Name Select the filed to use to generate the output file name.
This is a list of the interface options, all for exporting zone analysis data:
CAE Exchange You can export multiple HDF5 files, for your zone data.
Format
Beta CAE Ansa This is an export object to the BETA CAE ANSA tool.
Collier This is an export to Collier Hypersizer.

HyperSizer
MSC Patran Patran is a widely used pre/post-processing software for

Finite Element Analysis (FEA), providing solid modeling,
meshing, and analysis setup.
MSC SimXpert The Fibersim composite definition and SimXpert's FEA

definition are linked directly to the same CAD geometry. This
allows products to be designed, validated, and optimized
without having to translate volumes of data between
different software tools.
Generic BDF formats allow you to export the results of a detailed core
Format BDF sample for a given point. The point used to obtain the data is
specified in the target Design Stations, that represent areas
of constant thickness, and then the laminate stack-up at the
Design Stations origin location can be exported into BDF
format.
When exported, a single file (xx.bdf) lists all plies for which
analysis data has been created. This file also contains layup
information, including XYZ locations of each node, as well as
warp and weft fiber angles.

CAE Exchange Format
8.2.2.1 CAE Exchange Format

This object allows you to view data in an HDF5 file before any permanent Fibersim objects are created.
This import will display list of objects in the file from which Fibersim objects can be created. You can
import zone analysis data using this object.
The workflow is similar to the workflow for a ply-based CAE exchange:
1. Select a valid HDF5 file that fits the zone-based schema.
2. Press View Analysis File to display the relevant objects in the file, including materials, laminate
specifications (or material specifications), rosettes, zones, and curves.
3. Match up objects in the file with Fibersim objects where appropriate (some automated name-
matching may occur). If you import a new file into an existing import object, the links between
analysis zones and Fibersim zones will be maintained where possible.
4. Match up any analysis curves in the file with pre-existing features, or create features from the
analysis curves.
5. Selectively (or completely) update the Fibersim definition based on the analysis zones/materials/
laminate or material specification(s)/rosettes/curves.
Note that in the "Analysis Zones" window, the Stackup Change column indicates if the laminate
specification has changed. Options are "Not Linked", "No Change", "Different", "+ Thickness", or "-
Thickness".

CAE Exchange Format
MEMBER DESCRIPTION
Analysis This is the CAE file to be reviewed and imported. The file
Exchange File must be an HDF5 file format.
When you select the input file and press View Analysis File,
the file contents will display in the “Component Review” list
and a message will confirm what was loaded.
Last Modified This is the last modified date of the HDF5 file.
Date
Coordinate This is the reference coordinate system that will be applied

System to the imported data.

MSC SimXpert (Zone Import)
8.2.2.2 MSC SimXpert (Zone Import)
This object contains the MSC SimXpert file import options.
MEMBER DESCRIPTION
File The file containing zone data, generated from SimXpert.
Rosette The referenced rosette.
Options The two import options are:

MSC SimXpert (Zone Import)
• Create New Objects – always create new objects from the

import file, or update existing Fibersim objects.
• Update Existing and Create New Objects – update existing

Fibersim objects and create new objects

Laser Projection
8.2.3 Laser Projection
8.2.3.1 About Laser Projection
Fibersim-Laser Projection calculates the three-dimensional points used by laser projection systems, to
guide the laser path during projection for hand layup of composite plies. Laser projection data is
generated directly from the CAD model, ensuring projection accuracy and reducing data management
requirements. Generation of laser projection data from the CAD model eliminates the “teaching” step
often used to record the laser points used for projection, significantly increasing laser projection
productivity.
Laser Projection generates data for ply and core boundaries, displaying ply outlines on the layup tool.
These outlines aid in the location and orientation of plies during the layup process. Fibersim also
provides tools to include laser reference points, ply markers, and ply names. Laser Projection also
provides additional data that aids in the programming of multi-head systems for very large or highly
contoured parts, where a single projection head may not meet requirements. You can define a
customized laser format by generating XML data, and then transforming it using an XSL file. Laser
Projection currently supports all proper laser projection systems:
• Assembly Guidance LASERGUIDE
• Laser Projection Technologies
• GSI Lumonics OLT (Formerly from General Scanning, Inc.)
• Virtek Vision LaserEdge

Import Laser Projection Data (User Interface)
8.2.3.2 Import Laser Projection Data (User Interface)
This object allows you to import Fibersim-generated laser projection results back into the CAD system.
This data can be used to verify that the user-created data has been correctly configured, before the data
is used on the manufacturing floor.
MEMBER DESCRIPTION
Coordinate The coordinate system used for importing laser projection data. If this
System member is blank, Fibersim will use the CAD system’s master coordinate
system.

Import Laser Projection Data (User Interface)
Note:
Before importing laser data, you should be sure that the
Reference Coordinate system matches the coordinate system
that was used to create the laser data.
Units Units of the file to be imported. Valid values are inches and
millimeters.
Data File The laser projection file to be imported.
File Type Based on the data file selected, Fibersim detects the file type being
imported.
Review Displays a list of components being imported. When selecting a

Imported Data component, Fibersim highlights the laser data associated to the
selected component.
To create CAD geometry from the laser data, laser components need to
be edited.

Fiber Placement
8.2.4 Fiber Placement
The Fiber Placement section includes one object window, for the import of fiber path data.
8.2.4.1 ACE V2 Fiber Placement Import
The Report tab will contain summary data about the imported file, including:
• Number of plies in the file, and the number of plies matching existing Fibersim plies with material
in the object's laminate.
• Number of plies matching Fibersim plies that do not have a material assigned.
• An indication of whether plies are out of order. This will state if the order of the plies in the import
matches the sequence/step order in Fibersim.

ACE V2 Fiber Placement Import
MEMBER DESCRIPTION
Laminate Specifies the parent laminate.
Path Results File Select the input file
Boundary Type Whether fiber placement data will be exported for the
plies’ Net boundaries or Extended boundaries.
Coordinate System Specify a non-default coordinate system.
Geometry Display Options See section below.
Geometry Creation Options See section below.
Read Path Results Performs the import of the fiber placement data.
Geometry Display

MEMBER DESCRIPTION
Tow Add Point Style Select the style for the displayed points.
Tow Drop Point Style Select the style for the displayed points.

Show Course Edge Toggle the display of course edges.
Show Centerlines Toggle the display of path centerlines.
Show Path Direction Toggle the display of path directions.
Show Course Labels Toggle the display of path labels.
Centerline Width Select the width of the path lines.
Producibility Controls
Fiber Angle Deviation Toggle the use of fiber deviation in producibility results.
Roller Height Toggle the use of roller height in producibility results.
Radius of Curvature Toggle the use of radius of curvature in producibility results.
Collision Angle Avoidance Toggle the use in producibility results.
Geometry Creation
MEMBER DESCRIPTION
Non-Tangency Angle Specifies the angle when creating geometries.
Chord Tolerance Specifies the chord tolerance when creating geometries.

Output Curve Type Select the output curve type, either construction or result.

Preliminary Design Interface (Import)
8.2.5 Preliminary Design Interface (Import)
The Preliminary Design Interface Import utility allows you to import an Excel® file or tab-delimited text
file. The Import utility can setup a seed model, to modify an existing design outside of Fibersim.
SPECIAL NOTE: After performing a PDI import, a Zone-to-Layer update needs to

be run, to ensure the model is correct.

Preliminary Design Interface (Import)
MEMBER DESCRIPTION
File Select a valid Excel or tab delimited text file to be imported
Laminate The utility works on a laminate-by-laminate basis, so child

laminates must be processed separately.
Rosette Specifies the rosette to use when importing composite data,

when you have created new zones within exported data.
Import File The file type must be properly formatted:

Type
• MS Excel file
• Tab-delimited text file
Import Specifies the import method used by Fibersim:

Behavior
Create New Objects - create all of the objects contained in

the import file as new objects.
In most cases the Update Existing and Create New option

should be used. This will update any existing objects and
create new objects when the data is specified in the import
file.
Import Zone Options are Zones or Analysis Zones.

Type

Ply Import from Excel
8.2.6 Ply Import from Excel
This utility lets you import a ply table from Excel, or a csv file.
MEMBER DESCRIPTION
File Select a valid Excel file to be imported.
Rosette Select a proper rosette.

Ply Import from Excel
Import File The file type must be properly formatted:

Type
• MS Excel file
• Tab-delimited text file
Import Specifies the import method used by Fibersim:

Option
Create New Objects - create all of the objects contained in

the import file as new objects.
In most cases the Update Existing and Create New option

should be used. This will update any existing objects, and
create new objects when the data is specified in the import
file.

Composite Part XML Import
8.2.7 Composite Part XML Import
Once composite part has been exported (and processed by a customer specific interface), it can then be
imported back into Fibersim, using Composite Part XML Import.
MEMBER DESCRIPTION
Import File Specifies the composite data XML file to be imported.

Composite Part XML Import
Laminate Surface applied to the top-level laminate. The surface is

Surface projected on all imported component boundary curves.
If a laminate surface is not selected, boundaries are imported

as space curves.
Transform Optional XSL transform file used to format XML import files
File before being read into Fibersim.
If no XSL file is specified the file is imported as is.
Curve Type Whether Fibersim will create Result curves or Construction

curves.
Non- The angle of non-tangency determines whether imported curve

Tangency segments will be treated as single or individual segments.
Angle Adjoining curve segments that have a non-tangent angle below
the set value are treated as a single. Adjoining segments that
have a non-tangent angle above the set value will be treated as
individual segments.
Default value is 15 degrees and the acceptable range is greater

than or equal to 10 degrees, and less than or equal to 45
degrees.
Import Fibersim’s behavior when importing Composite XML data into a

Conflict part file that contains existing Fibersim data.
Rule
• Ignore if Existing – Fibersim will not import any
component data that has matching ID’s. For example, if
you export XML ply data from a given model, then change
a given ply’s step value, and then try to import the change
back into the existing model, this will not work with this
option, since the ply still has the same internal ID.
• Overwrite Existing – imports data that does not exist in

the target model. This option always imports all data
contained within the composite XML import file.

Wind Blade Design Import
8.2.8 Wind Blade Design Import
Manually creating a ply-based design of a wind blade is time-consuming, due to the number of plies.
You can set parameters in an excel spreadsheet, with minimal geometry input, to describe the plies.
That file can then be imported into Fibersim using this utility.
Access this from: File > Import > Wind Blade Design Import

MEMBER DESCRIPTION
Laminate The parent laminate, for the imported plies and rosettes.

Rosette Fiber directions will be measured relative to this rosette.
Input File File containing the data, to be used in the wind blade design.
Leading Edge This curve represents the leading edge of the part.
Trailing Edge This curve represents the trailing edge of the part.
Spar Cap The centerline that runs the length of the spar cap area.
Centerline
Spine Specifies the wind blade spine, to be used as an axis.
Result Type Whether Fibersim will create layers or plies.
Add Prefix to Names
Prefix In order to track the ply name independently from the layup
sequence, there spreadsheet columns called "Step" and "Sequence".
In the Step column, plies/layers are named based on the "Ply" column
(i.e. "1" becomes "PLY001" or "LYR001", "14b" becomes "PLY014b" or
"LYR014b").
This option lets you add the prefix, to specify the full ply name in the
spreadsheet. The "PLY" or "LYR" prefixes are used as the defaults. You
can also specify your own prefix, rather than the defaults.
Reverse Spine Reverses the orientation direction of the spine.

Direction
Segment Length Controls the number of points, for the creation of blade geometry.
Factor

Composite Part STEP
8.2.9 Composite Part STEP
A STEP file is a CAD-independent geometry data exchange file. Importing a STEP file allows you to create
a file with additional composite data.
SPECIAL NOTE: This feature requires a special license to access. Please contact
your Sales Representative for full details on this feature.

Export Options
8.3 Export Options
The ability to export data from Fibersim provides a quick, reliable way of transferring electronic
composite part data to analysts or manufacturing personnel.
8.3.1 Analysis – Ply

Analysis – Ply
MEMBER DESCRIPTION
Boundary Type Specify export of Net or Extended boundaries.
Allow Offset Simulation Check this option to use the offset simulation value (set
from the Ply “simulation options” menu).
Use Mapped Exports rosette-mapped orientation directions without

Orientations running a simulation.
Use Base Boundary Trims the output mesh back to the “nominal” boundary,
removing applied zone transitions.
Use Manufactured Part This will remove cutouts from the final result.
Include non-Structural Include non-structural materials in the export.

Materials
Export Rosettes as a This lets you export field-based rosettes to HDF5 and CP
Field XML. If the rosette is currently a non-field-based rosette, it
will be exported as a field-based one.
This is a list of the interface options, all for exporting ply analysis data:
Altair Fibersim data can be exported to Altair Hyperworks.

Hyperworks
Ansys ACP With this new export interface, fiber compression information can be
transferred from Fibersim into Ansys.
Beta CAE Ansa This is an export object to the CAE ANSA tool, with zone support.
HDF5

Analysis – Ply
Beta CAE Ansa This is an export object to the CAE ANSA tool.
CAE Exchange For large parts, Fibersim now makes it easier when exporting analysis
Format data for all plies at once. You can export multiple HDF5 files, consisting
of subsections of the plies of the parts, and then merge these files so
that one HDF5 file contains all of the plies.
CATIA Analysis Select the Laminate Surface and Update Parameter.
MSC Laminate The MSC Analysis Interface file format is compatible with PATRAN/
Modeler Laminate Modeler from the MacNeal-Schwendler Corporation (MSC). It
performs finite element analysis of composite structures. Two types of
analysis files are created:
• The master file contains filenames of each ply layup file for which
analysis data was generated. The file has the extension .fmd
(Fibersim-MSC Directory file), and is named from the Base File
Name parameter (e.g., LAM001.fmd.) The file contains a list of
analysis interface output files that were generated for the part, in
the sequence they were exported.
• This Ply Layup File contains analysis data for each individual ply.
Files use the extension .fml and are named from the Base File
Name parameter and the ply name, e.g., LAM001-P001.fml.
(Fibersim-MSC Layup File)
MSC Layup This interface writes CAE data in the .layup format.
MSC Patran Patran is a widely used pre/post-processing software for Finite Element
Analysis (FEA), providing solid modeling, meshing, and analysis setup.
Patran provides a rich set of tools that streamline the creation of
analysis ready models for linear, nonlinear, explicit dynamics, thermal,
and other finite element solvers.
From geometry cleanup tools that make it easy for engineers to deal
with gaps and slivers in CAD, to solid modeling tools that enable
creation of models from scratch, Patran makes it easy for anyone to
create FE models.

Analysis – Ply
MSC SimXpert Because Fibersim is completely integrated into commercial 3D CAD

systems, the Fibersim composite definition and SimXpert's FEA
definition are linked directly to the same CAD geometry.
This allows products to be designed, validated, and optimized without

having to translate volumes of data between different software tools.
NX Laminate For exporting NX Laminate Composite data.

Composites
PAM-RTM The PAM-RTM Analysis Interface file format is compatible with PAM-
RTM from ESI GROUP. This tool simulates the manufacture of composite
parts via the resin transfer molding process.
A single file is generated for all selected plies, containing orientation

data for each ply. The data has the same coverage as the plies in the
CAD model, and allows orientation information to be supplied to each
element of the mesh generated by the analysis software.
Generic BDF formats allow you to export the results of a detailed core sample
Format BDF for a given point. The point used to obtain the data is specified in the
target Design Stations, that represent areas of constant thickness, and
then the laminate stack-up at the Design Stations origin location can be
exported into BDF format.
When exported, a single file (xx.bdf) lists all plies for which analysis
data has been created. This file also contains Layup information,
including XYZ locations of each node, as well as warp and weft fiber
angles.
Generic The XML format is used to transfer fiber orientation data to various
Format XML analysis packages. XML data can be converted to any other data format
using XSL transformations, allowing for seamless integration with
virtually any application capable of importing data. Since XML is so
flexible, XML Analysis Interface files can be converted into various
customized file formats for use with commercial or proprietary software
packages.

Analysis – Zone
8.3.2 Analysis – Zone
The interface options under this section, are all for exporting zone analysis data:
MEMBER DESCRIPTION
Zones Specify the zones to be exported.

Analysis – Zone
Output Units Select the units for the output.
This is a list of the interface options, all for exporting zone analysis data:
CAE Exchange You can export multiple HDF5 files, for your zone data.
Format
Beta CAE Ansa This is an export object to the BETA CAE ANSA tool.
Collier This is an export to Collier Hypersizer.

HyperSizer
MSC Patran Patran is a widely used pre/post-processing software for

Finite Element Analysis (FEA), providing solid modeling,
meshing, and analysis setup.
MSC SimXpert The Fibersim composite definition and SimXpert's FEA

definition are linked directly to the same CAD geometry. This
allows products to be designed, validated, and optimized
without having to translate volumes of data between
different software tools.
specified in the target Design Stations, that represent areas
of constant thickness, and then the laminate stack-up at the
format.
When exported, a single file (xx.bdf) lists all plies for which
analysis data has been created. This file also contains layup

Analysis – Core Sample
8.3.3 Analysis – Core Sample
There are two interface options in this section, for exporting core sample analysis data. Both interfaces
share the same general layout.
MEMBER DESCRIPTION
Output Directory Directory where the output file will be located.
specified in the target Design Stations, that represent areas of
constant thickness, and then the laminate stack-up at the

Analysis – Core Sample

format.
When exported, a file (xx.bdf) lists all plies for which analysis
data has been created. This file also contains layup
Generic The FEMAP Export allows you to generate a Neutral file (.neu)
Format that contains the composite data. You need to define either
FEMAP zones or Design Stations that represent the constant gauge
areas of the part. Fibersim exports the data based on Design
Stations or zones.
The created file (xx.neu) lists all plies for which analysis data
has been created. It also contains layup information, including
XYZ locations of each node, as well as warp and weft fiber
angles.

Flat Pattern Export
8.3.4 Flat Pattern Export
The Flat Pattern Export interface generates flat pattern data files used by nesting and cutting systems.
Export files are generated for each flat pattern from information stored in Fibersim. Files contain all
necessary flat pattern geometry and manufacturing data for the nesting or cutting system.
This tool reduces the risk of incorrect data being transferred to the manufacturing cutter by
automatically creating flat pattern data and eliminating manual intervention by the user. This involves
not only transferring geometric data, but also manufacturing ply quantities, material types, orientations,
and labeling information.
Optimizes Flat Patterns for Cutting
You can fillet corners with a specified radius in order to optimize manufacturing productivity. Filleted
corners decrease cutting time by eliminating stop/start sequences, due to direction changes of the
boundaries.
You can also specify a fillet radius and a non-tangency angle, which specifies how sharp a corner must
be before it will be filleted. Fibersim detects the sharpest corner of the flat pattern and starts at that
location.
Flat Pattern Export supports a variety of nesting and cutting system formats, including:
• Cutting Edge
• DXF
• (A)GFM-NS2
• IGES
• Magestic
• Optimation

Flat Pattern Export
• JETCAM Expert ®
By creating flat pattern data files directly from the CAD model, data integrity is ensured by providing an
accurate representation of the geometry as stored in the CAD model.

Cutting Edge
8.3.4.1 Cutting Edge
Specify instructions for the exporting of flat pattern data to the Cutting Edge system.

Cutting Edge
MEMBER DESCRIPTION
Laminate The laminate specifies which plies are eligible for exporting.
Plies Plies to be exported. Select a range of plies, or a random sequence

of plies.
Boundary Type Flat patterns will be exported for the plies’ Net boundaries or
Extended boundaries.
Output Units Units of the generated export file. Inch (in) or Millimeter (mm).
File Format The output file end-of-line style.
Line Length Specifies the length of the smallest line segment in the flat pattern.
You can filter out small line segments in the exported pattern. When
exporting files, Fibersim removes all line segments smaller than this
value, and merges them into adjacent lines. This produces a
smoother flat pattern and optimizes it to increase cutting speed.
CUSTOMIZE
TOLERANCES
Non-Tangency Maximum angle of a non-tangency in the pattern, that will be

Angle preserved upon export. Values above this angle are eligible for
filleting, as long as a value is defined for the fillet radius. Valid
values are 5 - 60 degrees. Default value is 15 degrees.
Chord Tolerance Chord tolerance used when creating the file. Smaller tolerances
result in finer tessellation, larger ones in a coarser tessellation.
Values between 0.1524 mm (0.006 in) and 7.62 mm (0.30 in).
Offset Flat Offset all ply information to first quadrant of the coordinate system.
Pattern
Export Origin Whether Fibersim will export the origin point of the pattern.
NOTE: In certain export formats, Yes means the origin will be cut
into the flat pattern.
Export Direction Whether Fibersim will export the direction of the flat pattern.

Cutting Edge
NOTE: In certain export formats, Yes means the direction will be cut
into the flat pattern.
Export Markers Whether Fibersim exports markers defined on the flat pattern.
NOTE: In certain export formats, Yes means markers will be cut into
the flat pattern.

DXF
8.3.4.2 DXF
SPECIAL NOTE: The DXF format options are the same as in the section Cutting
Edge. The DXF-specific “Options” pop-up menu is shown below.
The members under the special “DXF Options” pop-up menu are listed here.
DXF Options
MEMBER DESCRIPTION
Polyline Specifies how the DXF file will be created:

Format
• Polyline - generic format that outputs flat pattern entities (flat
pattern, holes, markers, etc.) as individual polylines, which can be
output as lines or lines and arcs. Vertex information must be
included in the DXF file.

DXF
• Primitive - generic format defining all geometry as a set of

individual lines or lines and arcs. Unlike Polyline, this does not
require vertex information.
• AAMA - output is formatted in accordance with American Apparel

Manufacturers Association (AAMA) standards. Requires all
geometry to be generated as polylines and that turn point
information be included in the DXF file. The AAMA standard
requires two blocks of textual information. Fibersim generates
these two blocks of text annotations. When importing AAMA files
into a DXF reader, these annotations appear as text elements.
Boundary Layer that the ply boundary will be placed on (in the export file).
Layer Default is 0.
Holes Layer Layer that ply holes will be placed on (in the export file). Default value
is 0.
Origin Layer Layer that ply origin will be placed on (in the export file). Default value
is 0.
Direction Layer that ply direction will be placed on (in the export file). Default is
Layer 0.
Markers Layer Layer that the ply markers will be placed on (in the export file). Default
is 0.
Export Text Whether Fibersim will include the ply name with exported patterns. Ply
names originate at the pattern origin and propagate based on the
direction curve. Text that is exported with the pattern is determined by
the ply object’s name.
Height Height of the ply name text that is exported with the flat pattern.
Default value is 25.4 mm or 1 inch.
Note:
Only used when Export Text is set to “Yes”.
Layer Layer that ply name text will be placed on (in the export file). Default is
0.
JOIN NMAES
Name Specify the separator character between the names.

separator
AUTO FORMAT TEXT

DXF
Constraints You can use these options to have Fibersim automatically format the
text. It is no longer necessary to review each exported pattern and
manually fix text issues on small plies.
You can shift the position of the text, linearly along the direction of the
text. Or, you can shrink down the size of the text (resize), and the third
option is to rotate the text.
AAMA Grade Grade rule table, used for the DXF input file. (See below.)
Rule Table
Name Note:
Only used when Polyline Format is set to “AAMA”.

(A)GFM-NS2
8.3.4.3 (A)GFM-NS2
SPECIAL NOTE: The (A)GFM-NS2 format options are the same as in Cutting
Edge. The (A)GFM-NS2-specific “Options” pop-up menu is shown below.
Members for the special “Options” pop-up menu are listed here.
MEMBER DESCRIPTION
180 Allow for 180 degree nesting angles.
Polyline Format Specifies how the file will be created:

(A)GFM-NS2
• Polyline - generic format that outputs flat pattern

entities (flat pattern, holes, markers, etc.) as individual
polylines, which can be output as lines or lines and
arcs. Vertex information must be included in the DXF
file.
• Primitive - generic format defining all geometry as a
set of individual lines or lines and arcs. Unlike Polyline,
this does not require vertex information.
Boundary Layer Layer that the ply boundary will be placed on (in export
file).
Holes Layer Layer that ply holes are placed on (in the export file).
Origin Layer Layer that ply origin will be placed on (in the export file).
Direction Layer Layer that ply direction will be placed on (in the export file).
Markers Layer Layer that ply markers will be placed on (in the export file).
Export Text
Whether Fibersim will include the ply name with exported patterns. Ply names
originate at the pattern origin and propagate based on the direction curve. Text
that is exported with the pattern is determined by the ply object’s Name.
Height Height of the ply name text that is exported with the flat
pattern. Default value is 25.4 mm or 1 inch.
NOTE: Only used when Export Text is set to “Yes”.
Layer Layer that ply name text will be placed on (in the export
file).
JOIN NAMES
Name separator Specify the separator character between the names.
Auto format text
Constraints You can use these options to have Fibersim automatically

format the text. It is no longer necessary to review each
exported pattern and manually fix text issues on small plies.

(A)GFM-NS2
You can shift the position of the text, linearly along the
direction of the text. Or, you can shrink down the size of the
text (resize), and the third option is to rotate the text.

IGES
8.3.4.4 IGES
SPECIAL NOTE: The IGES format options are the same as in Cutting Edge. The
IGES-specific “Options” pop-up menu is shown below.
Members for the special “IGES Options” pop-up menu are listed here.
MEMBER DESCRIPTION
Export Text Whether Fibersim will include the ply name with patterns being
exported. Ply names will originate at the flat pattern origin and will
propagate based on the flat pattern direction curve.
Note:
Text that is exported with the flat pattern is determined by the
ply object’s Name.

IGES
Height Height of the ply name text, that is exported with the flat pattern.
Note:
Only used when Export Text is set to “Yes”. Default value is 25.4
mm or 1 inch.
Layer The layer that the ply name text will be placed on (in the IGES export
file). Enter an integer value. Default value is 0.
Join Names
Name Specify the separator character between the names.

separator
Auto format text
Constraints You can use these options to have Fibersim automatically format the
text. It is no longer necessary to review each exported pattern and
manually fix text issues on small plies.
You can shift the position of the text, linearly along the direction of the
text. Or, you can shrink down the size of the text (resize), and the third
option is to rotate the text.

Optimation
8.3.4.5 Optimation
SPECIAL NOTE: The Optimation format options are the same as in Cutting Edge.
The Optimization-specific “Options” pop-up menu is shown below.
Optimation nesting systems require two separate files for each exported flat pattern.
• IGES file – contains geometry definition of the flat pattern
• “.ppi” file – contains additional information to nest flat patterns efficiently. (“ppi” = Pre-
Programmed Input.) The difference between the Optimation and JETCAM ppi file is the addition of
the (+ASSEMBLY LAM001,1+) line in JETCAM.
Members in the “Optimation Options” pop-up menu get output to the “.ppi” file.
MEMBER DESCRIPTION
Class The class rating, and part shape. Valid values are:
• 1 – a circular shape
• 2 – a rectangular shape
• 3 – an irregular shape
Grain Whether the ply can rotate by 90× (N) or only by 180× (Y). This
member specifies whether the ply has a directional
dependence based on the materials warp and weft direction.

Optimation
The Y/N indicates if the pattern is constrained to a grain

direction.
180 Indication that the pattern can be rotated 180 degrees for
nesting.
Work Center The 5-character work center name.
Minimum Whether there is a minimum space between patterns. This

Space informs the nesting system that adjacent patterns require
spacing.
Revision The revision level of the flat pattern file.
Holes Number of internal holes. Should always be set to 0, which is

the default.
Gangform The order requirement, if one final part is required. Default

value is 1. Modify this member as needed.
Additional .ppi file parameters
There are three additional parameters in the .ppi file that are not part of the “Optimation Options tab”:
• PARTNO – a combination of the part number and the ply name.
• RAWMAT – set depending on the material specified in the ply form.
• NAMLOC – specifies the location of the ply label text.
The values for these parameters are obtained from the Ply form.
Fibersim automatically exports the ply label text location for Optimation systems. Fibersim uses the
coordinates of the 2D Ply origin and ply direction to locate and align the ply label text, since the ply
origin is always within the flat pattern boundary. By default, Fibersim generates flat patterns such that
the 2D ply origin is positioned at the origin of the current 2D coordinate system (i.e., X,Y = 0,0).
Upon importing IGES files, Optimation translates all geometry to the first quadrant of its coordinate
system, such that all geometry X,Y values are at their minimum positive values.

Optimation
Note:
Optimation does not translate the ply label text location contained in
the “.ppi” file to the first quadrant. If ply label text is being plotted by
Optimation, the text may occur outside the boundary of the flat pattern.

JETCAM Expert ®
8.3.4.6 JETCAM Expert ®
SPECIAL NOTE: The JETCAM Expert format options are the same as in Cutting
Edge. The JETCAM Expert-specific “Options” pop-up menu is shown below.
Members for the special “JETCAM Expert Options” are listed here.
MEMBER DESCRIPTION
PPI Settings
Revision The revision level of the flat pattern file.
Allowable Rotation Allowable rotation angles for nesting the flat patterns.

JETCAM Expert ®
Material Call Out Attribute in the material database that that will
distinguish that material in the .ppi file's RAWMAT line.
Additional Options
Export Format The export file format, DXF or IGES.
Origin Layer Specified layer for the origin.
Boundary Layer Specified layer for the boundary.
Markers Layer Specified layer for the markers.
Direction Layer Specified layer for the direction.
Closed Markers Specified layer for the closed markers.

Layer
Export Text Whether or not to export ply name text.
Height Height of the export text.
Layer Layer to contain the export text.
Join Names
Name separator Specify the separator character between the names.
Auto format text
Constraints You can use these options to have Fibersim

automatically format the text. It is no longer necessary
to review each exported pattern and manually fix text
issues on small plies.
You can shift the position of the text, linearly along the
direction of the text. Or, you can shrink down the size
of the text (resize), and the third option is to rotate the
text.

Laser Projection
8.3.5 Laser Projection
8.3.5.1 Assembly Guidance
Laser Projection supports the Assembly Guidance laser projection system.

Assembly Guidance
MEMBER DESCRIPTION
Laminate Select the laminate to export.
Note:
For a top-level laminate, all children plies are eligible
for export. For a child laminate, only that laminate
(and its children) are eligible.
Start The first ply to be exported.

Component
End The last ply to be exported.

Component
Boundary Type Whether laser projection data is exported for the plies’ Net
boundaries or Extended boundaries.
Output Location where the laser projection export file will be

Directory written.
SPECIAL NOTE: Avoid selecting a folder with an ampersand

(&) in the name, or anywhere in the directory path. This may
cause errors with data generation.
File Name Prefix of the laser projection data file. Options are:
• <Laminate Name>
• <Laminate Part Number>
• <Model Name>
• User-specified name
Points Defines the reference or target points used to calibrate the

laser system. You can select an unlimited number of points.
Coordinate The coordinate system used to generate XYZ values, for

System laser data points. If blank, Fibersim uses CAD system master
coordinate system.
NOTE: Before exporting laser data, be sure that the

Reference Coordinate system matches the coordinate
system being used on the manufacturing floor.
Export To Check this option to export the data:

Assembly Guidance
• File - In the Output Directory field, define an on-disk

location to save the export.
• Teamcenter - The Output Directory field will be read-

only and will display <Teamcenter> in the path field.
Options See below.
(Pop-up menu)
Options
MEMBER DESCRIPTION
Output Units Units of the laser data file. Defaults are CAD display units.
Step Length Maximum distance in between tessellated boundary points, on

relatively straight boundary sections. Fibersim first creates
laser data tessellation points, then applies additional points,
based on this value.
Note:
On long flat surfaces, Fibersim only creates two points
for a line segment, which may not be enough for the
laser projection system. In these cases, the maximum
step length should be used to add points.
Exclude Excludes darts.

Darts
Exclude Excludes Minimum Course Corners.

Minimum
Corners
Offset Whether laser projection data will be offset from the laminate
surface.
Include Whether or not normal data will be included in the laser

Normals projection file. Writing normal data to laser projection data file
enables a multi-head projection system to determine which
head will project each point.
Get Normals When Fibersim inserts points on a boundary, it will typically

from Surface average the normals of the two points between which the new
point is inserted. This option lets you override this behavior
and have Fibersim obtain the normal value from the surface
directly.

Assembly Guidance
Note:
This may increase time it takes to generate the export
data but it eliminates any approximation errors for the
inserted point normals.
Projection Check options to determine if the laser file includes:

Controls
• ly origin data
• fiber direction data
• marker data
Shrink Data Whether or not the laser projection file will include a shrink
factor.
Factor Specifies the amount that the laser projection will shrink plies.
Note:
Only applied if Shrink Data is set to “Yes”. Default is 1,
which will not shrink the data. You should specify a
factor smaller than 1 if the desired data is to be shrunk.
Location The point in which all Plies will shrink around.
Note:
Only applied if Shrink Data is set to “Yes”, and a Shrink
Factor other than 1 is specified. (Select a single 3D
point.)

List of the other Laser export format options
8.3.5.2 List of the other Laser export format options
The list of remaining export laser options includes:
EXPORT FORMAT DESCRIPTION
General Create a file that will interface with the general scanning
Scanning format.
LAP Create a file that will interface with LAP.
LPT Create a file that will interface with LPT.
SL Create a file that will interface with SL.
Virtek Create a file that will interface with Virtek.
Virtek v4 Create a file that will interface with Virtek v4.
XML Create a file that will interface with XML.
Custom Create a custom interface file.

Defining Reference Points
8.3.5.3 Defining Reference Points
Reference points are three-dimensional locations used to calibrate a laser system. These points are
defined in each laser projection format with the Reference Points member (under the “Standard” tab).
You can select an unlimited number of points to be used as reference or target points.
Each laser projection system handles reference points in a different manner:
SYSTEM HANDLES REFERENCE POINTS
Assembly Must have reference point data within the actual laser
Guidance projection data file. (Does not use a separate calibration file.)
If Reference Points are selected, they are included in the laser

projection file.
General Can use either the calibration data within the laser projection
Scanning data file, or as a separate file.
Laser Format
If Include Reference Points is set to Yes (Options tab)

reference points are included in the laser projection data file.
LAP Laser Use separate files for laser projection data and calibration
Format point data.
LPT Laser
Format
SL Laser
Format
Virtek Laser
Format
XML Based Fibersim’s laser data module can generate laser projection
Laser data in XML to offer flexibility in creating specialized laser
Projection data formats.
Data
A laser file created in XML format can be transformed using

XSLT into a desired format. After selecting an XSLT file,

Defining Reference Points
Fibersim generates an XML file and then transforms it with

the inputted XSLT.
Notice in the $FIBERSIM_HOME/xslt_files directory there are

four other XSL files, that Fibersim uses to create the LPT file
format, and the Virtek V4.2 file format. If you wish to
generate customized file formats, then the a new XSL file
should be used.
SPECIAL NOTE: We will work with customers on a consulting

basis for creating customized files. Contact your account
manager to inquire about consultation for customized laser
projection XSL files.
Custom Laser A laser file created in XML format can be transformed using
Projection XSLT into a desired format. With the Custom format, you can
Data do this all in one step.

Fiber Placement Interface
8.3.6 Fiber Placement Interface
The Fiber Placement Interface product acts as a data translator to the ACRAPLACE and ACEV2 Fiber
Placement software. You can generate input to the ACRAPLACE and ACEV2 systems directly from the
composite part definition.
Fiber placement machines combine the advantages of filament winding, contour tape laying, and
computer control to automate the production of complex composite parts that conventionally require
extensive hand layup. Using fiber placement machines can reduce costs, cycle times, structural weight,
and handwork/rework when manufacturing composite parts, but creating data files to drive the
machines is tedious, time consuming, and error-prone.

Fives Cincinnati – ACRAPLACE
8.3.6.1 Fives Cincinnati – ACRAPLACE
Exports three-dimensional part geometry, and Fibersim data to ACRAPLACE, Cincinnati Machine’s (CM)
fiber placement programming software, using CM's fiber placement language (FPL).
Fibersim creates import files for ACRAPLACE that accurately represent part layup surfaces, ply
definitions, ply orientation information, region information, and unique fiber placement entities.
MEMBER DESCRIPTION

Laminate Select the laminate to export.
NOTE: For a top-level laminate, all plies and its children are
eligible for export. For a child laminate, only this laminate
(and its own children) are eligible.
Ply List Plies to be exported.
Boundary Fiber placement data will be exported for Plies’ Net

Type boundaries or Extended boundaries.
Start Number The start value for ply labeling in the generated fiber
placement file. Must be an integer > 1. Default is 10.
Increment The increment for ply labeling in the generated file.
This must be an integer > 1. Default is 10, meaning each ply

number increments by ten.
Generate
Base Surface
Generate
Child Surface
Step Length
Chord
Tolerance
Alignment Mandrel alignment definition used when generating the data

Type file:
• Frame: Also called the Design-To-Machine-Three-Point

definition. Used when relationship of the mandrel
surface to the mandrel shaft is not well known.
• Shaft: Used when relationship of the mandrel surface to

the mandrel shaft is precisely known. Requires three
points to describe the relationship of the mandrel to the
fiber placement machine’s rotation axis.
• Multi Point: When relationship of mandrel surface to
the mandrel shaft is not well known. Designed to
iteratively use frame alignment techniques to better

distribute alignment errors, and to be expandable to

more than three points.
Alignment 3D points used in the alignment process. Select points, based

Points on the alignment type selected in Alignment Type.
Fiber Axis The ACRAPLACE system requires definition of a fiber axis,

which defines the zero degree orientation. Axis can be a 3D
curve, line, arc or spline.
Axis should be created in the direction such that the first end-
point is on the side of the fiber placement machine’s head
stock. The other end point will be on the side of the machine’s
tail stock.
Regions Regions applied to the Fiber Placement export file. Regions

control specific machine parameters, in user-defined areas or
regions.

Fives Cincinnati – ACE V2
8.3.6.2 Fives Cincinnati – ACE V2
Regions allow you to define machine parameters in specific areas of the tool surface. The regions are
assigned a priority to alleviate problems where more than one region shares the same tool area.
MEMBER DESCRIPTION


Ingersoll
8.3.6.3 Ingersoll
Transfer composite data from Fibersim directly into Ingersoll’s CPS software.

Ingersoll
MEMBER DESCRIPTION
Laminate Specifies which plies will be eligible for exporting.
For a top-level laminate, all plies are eligible for export.
Ply List Plies to be exported.
Reference Specify a reference coordinate system.

Coordinate
System
Regions Regions to apply to the Fiber Placement export file. Regions

control specific machine parameters in user-defined areas or
regions.
Spine The spine for the data being exported. You can select more
than one curve, but curves must be continuous.
Boundary Type Whether Fiber Placement data will be exported for the plies’
Net Boundaries or Extended Boundaries.
Directory Location where the fiber placement export file will be

written.
Output File Name of the fiber placement export file. Options are:
Name
• Laminate Name
• Laminate Part Number
• Model Name
• User-specified name



Ingersoll
Tools Information tab
MEMBER DESCRIPTION
Machine Alignment - Define Shaft Alignment Manually
This option lets you select the necessary three points manually, to define the
shaft definition.
Choose a Reference Origin, Axis Point and Upward Direction.
Reference Origin Reference Origin (and Axis Point) define the

ends of the shaft.
Axis Point Reference Origin (and Axis Point) define the

ends of the shaft.
Upward Direction This point defines the upward direction from

the shaft axis.
Machine Alignment - Use Machine Coordinate System
This option lets you link to coordinate system already defined in the model,
which greatly simplifies the process.
Machine Coordinate System Specify a coordinate system from the model.

Use this option when Use Machine Coordinate
System is chosen.
Tool Definition
Puck/Sphere Diameter Diameter of the alignment pucks/spheres.
Tool Alignment Point The XYZ location of the first puck/sphere.
Puck/Sphere Orientation Point or line that establishes a direction vector

for the tool orientation.

CGTech - Vericut Composite Programming
8.3.6.4 CGTech - Vericut Composite Programming
This is the CGTech interface.

CGTech - Vericut Composite Programming
MEMBER DESCRIPTION
Laminate Select a parent laminate for the plies to be exported.
Ply List Select the plies to be exported.
Boundary Type Whether to export net or extended ply boundaries.
Reference Select a machine coordinate system to specify alignment

Coordinate of the machine.
System
Machine Select a machine coordinate system to specify alignment

Coordinate of the machine.
System
Boundary Lap Percentage of tow width allowed to overlap the ply

boundary.
Angle Tolerance The angle tolerance value used when generating paths.
Course Lap Percentage of tow width allowed to overlap between

adjacent courses.



Coriolis – CAD Fiber
8.3.6.5 Coriolis – CAD Fiber
This is an interface to the Coriolis CAD Fiber product.

Coriolis – CAD Fiber
MEMBER DESCRIPTION
Ply List Select the plies to be exported.
Coordinate System Specify a reference coordinate system.
Reference Type - Options are Rosette or Curve.
Rosette - Alignment
Points
Curve - Fiber Axis
Curve - Alignment
Points
Output Units Units are either inches or millimeters.
Boundary Lap Percentage of tow width allowed to overlap the ply

boundary.
Minimum Gap The length value for the smallest allowable gap
between courses.
Sphere Diameter Diameter value of he size of the reflector sphere,

used for laser positioning of the tool.
Maximum Angle
Deviation
• File - In the Output Directory field, define an on-

disk location to save the export.
• Teamcenter - The Output Directory field will be

read-only and will display <Teamcenter> in the
path field.

Automated Tape Laying Interface
8.3.7 Automated Tape Laying Interface
8.3.7.1 Fives Cincinnati – ACE V2
This interface lets you export a file from Fibersim into the ACEV2 Tape system.
MEMBER DESCRIPTION

Laminate Plies eligible for exporting.
NOTE: If the top-level laminate is chosen all plies are

eligible for export.
Laminate See below.

Options
Boundary Type Whether tape laying data is exported for the plies’ Net or
Extended boundaries.
Ply Information
Ply List Defines the plies to be exported.
Start Number The start value for ply labeling in the generated tape laying
file. Default is 10.
Increment Sets the increment for output ply numbers. Default is 10,
meaning each ply number increments by ten.
Trim Reference
Trim lines are used for flat tape laying machines. These tape
laying machines will apply some number of layers then trim
the part on the table. The "trim lines" are the cuts that the
machine will make on the flat part.
This field allows you to select/create a "trim reference"

object, and pick a number of open curves (Trim Lines) and
specify start points (Trim Line Start Points) for the curves.
Note that you do not have to specify a complete boundary
(you might just trim an edge or part of a boundary).
By specifying an After Ply value using a ply sequence

number, you can indicate when the trim is applied.
Currently, Fibersim only applies one trim operation at a
sequence. You should not create trim operations with the
same sequence number for the After Ply value, since only
the first trim will be applied.
Alignment Options
Alignment Type Mandrel alignment definition used when generating the

data file:

• Frame: Also called the Design-To-Machine-Three-Point

definition. Used when relationship of the mandrel
surface to the mandrel shaft is not well known.
• Shaft: Used when relationship of the mandrel surface

to the mandrel shaft is precisely known. Requires three
points to describe the relationship of the mandrel to
the fiber placement machine’s rotation axis.
• Multi Point: When relationship of mandrel surface to

the mandrel shaft is not well known. Designed to
iteratively use frame alignment techniques to better
distribute alignment errors, and to be expandable to
more than three points.
Alignment 3D points used in the alignment process. Select points

Points based on the alignment type selected in Alignment Type.
Acraline Points Allows for the definition of the machine alignment through
the use of three points, called Acraline Points.
This type of alignment is used by the tape-laying machine

to make small adjustments for positioning (i.e., fine
tuning). Other alignment types (i.e., frame align, shaft
align, etc.) are for making large adjustments.
Fiber Axis The tape laying system requires the definition of a fiber
axis. This axis defines the zero degree orientation. The axis
can be a 3D curve, line, arc or spline.
Preferably, the axis should be created in the direction so

that the first end-point is on the side of the fiber placement
machine’s headstock. The other end point is on the
machine’s tailstock.
Regions Regions to be applied to the tape laying export file. Regions

control specific machine parameters in defined areas or
regions.
Programming Specify the coordinate system.

Coordinate
System
Scrap Areas Links a Scrap Area object to the ACEV2 Tape object.
Output
File Format Designates the data file format of the fiber placement
export file.

• Standard - writes FPPL file as a stand-alone file to be

used by itself in ACRAPLACE. Used when creating a file
for a new part.
• Partial Translational - writes an FPPL file that must be

appended to an existing file in ACRAPLACE. This is
used when replacing a single ply boundary to an
existing standard file.
File Name Field to use to generate the output file name.
Units Either inches or millimeters.



MikroSam
8.3.7.2 MikroSam
This interface lets you export a file from Fibersim into the MikroSam Tape system.
MEMBER DESCRIPTION
Plies Select plies to include in the export.
Alignment 3D points used in the alignment process.

Points
You must select three alignment points for this export to be

successful.

MikroSam
Boundary Type Either the course net or extended boundary.
Output Select the directory where the output file will be stored.
Directory
Output File Prefix given to the export file.

Prefix
• File - In the Output Directory field, define an on-disk location to

save the export.
• Teamcenter - The Output Directory field will be read-only and
will display <Teamcenter> in the path field.

Broadgood (Tecnomatix)
8.3.8 Broadgood (Tecnomatix)
This is an interface to export into Tecnomatix.
MEMBER DESCRIPTION
Tool Surfaces Select the tool surfaces.
Laminate Parent laminate for the exported plies and rosettes.
Courses Select the courses to include in the export.

Broadgood (Tecnomatix)
Directory Directory where the exported file will be placed.
File Prefix Prefix given to the export file.

Preliminary Design Interface (Export)
8.3.9 Preliminary Design Interface (Export)
The Preliminary Design Interface lets you export composite data. You have the option to export data
directly to an Excel® file, or to a tab-delimited text file.
The data that gets exported from Fibersim is broken into four blocks of information, all of which you can
make changes to once in Excel®:
• Material Specifications
• Laminate Specifications
• Zones
• Layers
Once the changes are complete, you can import the date back into Fibersim.

Ply Export to XML
8.3.10 Ply Export to XML
This lets you export composite ply data in XML format.
MEMBER DESCRIPTION
File Name Select the name and location for the generated output file.
Laminate Specifies zones, plies and/or cores eligible for exporting.

Ply Export to XML
Export File Type Specifies the type of export file, MS Excel file or Tab-delimited
text file. Either file type must be properly formatted.
Export All Child Check this option to have all child components exported.
Components

Composite Part XML
8.3.11 Composite Part XML
Composite Part XML lets you export composite part data in XML format.
Exported XML data can be used as an input to a customer specific interface.

Composite Part XML
MEMBER DESCRIPTION
Output Directory Location on the file system where composite data will be
written.
File Name The field used to generate the output file’s name.
Objects to Export Lets you select which objects to export, either:
• All objects – all Fibersim objects
• Specified objects – only selected zone/component

objects
Export Rosettes as This lets you export field-based rosettes to HDF5 and CP
a Field XML. If the rosette is currently a non-field-based rosette,
it will be exported as a field-based one by checking this
option.
Step Length Maximum triangle segment length allowed while

creating a triangulated surface representation of the
underlying part. This value controls resolution of the
triangulated surface being exported. Small values will
generate more triangles, even in flat sections of the
model.
Default value is 76.2 mm (3.0 in) for the laminate

surface. Valid range for this value is 6.4 – 610 mm (0.25
– 24 in).
Note:
Used when Export Laminate Surfaces is selected.
Chord Tolerance Maximum distance allowed between the triangulated

surface representation and the Laminate surface. Small
values will generate more triangles in high curvature
areas of the part.
Default value is 1.01 mm (0.040 in) for the Laminate

surface. Valid range is 0.25 – 51 mm (0.01 – 2 in).

Composite Part XML
Export Zone Adjacency Data - zone adjacency is included with the Composite
Part XML Export data.
Zone Table Specifies whether a percentage or ply count is included

for each ply orientation.
Selected objects
Laminate Specifies zones, plies and/or cores eligible for exporting.
Components Specific components to be exported.
Zones Select which zones, if any, should be included in the

exported composite data.

Composite Part STEP
8.3.12 Composite Part STEP
This interface allows you to export composite data from a STEP file.
SPECIAL NOTE: This feature requires a special license to access. Please contact
your Sales Representative for full details on this feature.
MEMBER DESCRIPTION
Boundary Type You can only export either the Net or Extended boundary
information, but not both.
STEP File Select the STEP file you want to export.
Export STEP File Performs the export.

Composite Part STEP

9. Chapter 9: Volume Fill
9.1 Introduction
This utility allows you to create layers of materials to fill a structural volume on your model’s laminates.
Using this utility, the gap between an upper and a lower surface can be filled with plies.
9.2 Volume Fill Utility
This is the interface for the volume fill utility.
MEMBER DESCRIPTION

Volume Fill Utility
Laminate Select the parent laminate that contains the materials

that need a fill volume applied.
Rosette Specify the proper rosette. Fiber angles will be

measured relative to the chosen rosette.
Fill to Surface Select the surface that completes the volume to be

filled.
Orientation Pattern Enter the orientation repeat pattern that will be used
to fill the volume. (This is repeated through the
thickness.) Enter a comma-separated list.
Join Curves
Layer Boundaries
Generate/Update Generates the layers and fills in the volume. Note that
Layer Surfaces the layers will inherit the default material from the
laminate.
Layer Surfaces
Layers will be colored by their orientation.

Details of Volume Fill Functionality
9.2.1 Details of Volume Fill Functionality
9.2.1.1 Changes in Normal Orientation of Fill To Surface (to define volumes)
Prior to the 15 release, the orientation of the Fill To Surface normal was in the same general direction as
the Layup Surface. For the 15 release the orientation of the Fill To Surface normal, must now point
towards the volume to be filled.
This is necessary to provide better visual indications of the volume being filled. It also provides
consistency in defining normal orientations between the Layup surface and Fill To surface.
Part setup for pre-15 releases of Fibersim
For new parts, you will need to ensure that the surface normal points toward the volume being filled. In
this example, the Laminate and Fill To Surface for a legacy part are displayed.

Changes in Normal Orientation of Fill To Surface (to define volumes)
Part setup with Fill To Surface normal reversed

Multiple Fill To surfaces
9.2.1.2 Multiple Fill To surfaces
Prior to the 15 release, Volume Fill did not handle volumes with either of the following:
• Near perpendicular surfaces
• Surfaces with a smaller cross section at lower step values than upper step values.
You can now fill such surfaces using multiple Fill To surfaces. For example, in the image below, there are
three Fill To Surfaces with their normal highlighted in magenta. The surfaces on the left and right side
are angled such that they are underneath the top surface.
Fill-To surface with near perpendicular faces
There are two steps involved in setting up the volume:
If you have a volume with a smaller cross section at lower step values than upper step values:
1. In cases where the normal from the laminate makes multiple intersections with the surface, the
volume needs to split as shown below.

Multiple Fill To surfaces
2. The multiple surfaces need to be selected as the Fill To Surface.

Highlighting options
9.2.1.3 Highlighting options
The highlighting controls for Laminate and Fill To surfaces provide visual feedback to verify normal
orientation and laminate boundaries.

Ply simulations using Offset surfaces on by default
9.2.1.4 Ply simulations using Offset surfaces on by default
Plies created from layers generated from the Volume Fill process have the option of running a simulation
on the offset surface. Prior to the 15 release, the option to use the offset surface was off by default. For
newly created volume fill objects, this option will be on by default.
Also, the 'Traditional' method is the only valid simulation method for plies that are using the offset layer
surface. Plies that use the offset layer surface for the simulation will not be allowed to change to any
other simulation method.
The Simulation Surface member on the ply will indicate "Volume Fill Skin" for plies that will be using the
offset layer surface from Volume Fill.

These offset layer surfaces are trimmed to either the layer net or extended boundary. The laminate's
Design Boundary setting is used to define the boundary type. Therefore, a ply that uses an offset layer
surface for the simulation will only be allowed to simulate for the boundary type for which the surface
was created.
Note that users can still control whether the ply will use the laminate surface or the offset layer surface
from the Volume Fill form. Check or uncheck the Enable for Simulation option as needed.


Additional full body layer is no longer generated (by default)
9.2.1.5 Additional full body layer is no longer generated (by default)
In prior releases, when Volume Fill generated layer surfaces, an extra full body layer was created as the
final layer. This layer was always created regardless of the height of the volume.
In the current release, Volume Fill will no longer automatically create a full body layer as the final layer.
Only layers required to fill the volume will be created.

Laminate Design Boundary used for layer curve assignment
9.2.1.6 Laminate Design Boundary used for layer curve assignment
The layers generated by Volume Fill will have boundary curves assigned to either the Net or Extended
boundary. This is controlled by the Design Boundary setting on the laminate to which it is linked.
In prior releases, generated layer curves were always assigned to the Net boundary.



10. Index A: Materials and Machine
Databases
10.1 Introduction
All Fibersim data is communicated using XML technology. XML defines the Materials Database and the
Machine Database.
The files, MaterialsDB.xml and MachineDB.xml contain default materials and machine specifics are
included with each distribution of Fibersim, at the following location:
$FIBERSIM_HOME/FiberSIM/databases
The materials describe a broad range of material types, and are representative of a typical material in
each category.
Note:
You are encouraged to test the materials you are using, and enter the
appropriate values into the database.

How to Edit a Database
10.2 How to Edit a Database
10.2.1 Editing XML
Editing XML files can be done with a variety of programs, such as a standard text editor. Other editors,
such as XML Spy, produced by the Altova Corporation, are designed specifically for viewing and
manipulating XML files.
Examining the structure of XML, it is easy to break up each part of the file into start tags,<>, and end
tags, </>. The information between start and end tags is said to be contained within the tags.
In the Materials Database, this means that information contained between the start and end tags will
describe certain properties of the material. For example, each material is contained within a material
start tag, <Material>, and a material end tag, </Material>.
It is important to note that tags must always come in pairs. A file that is missing a start or end tag will
not function properly in Fibersim. An example material entry would look like this:

Editing XML
When you ready to design parts with Fibersim, it will be necessary to customize materials specific to a
part being designed.
Contained within each set of material tags is a series of tags for each material parameter. Between each
of the parameter tags will be the current value set for that parameter.

Adding a Material to the Database
10.2.2 Adding a Material to the Database
The following steps are necessary to add a new material to the database:
1. Open the MaterialsDB.xml file, located at:
$FIBERSIM_HOME\FiberSIM\databases
2. Create a new material start tag, <Material>. This should be placed on a new line that follows any
material end tag, </Material>.
3. Insert each of Material tag, including the new values between each set of tags.
4. Complete the material definition by creating a material end tag, </Material>.
– Or –
1. Open the MaterialsDB.xml file.
2. Highlight and copy a previous material definition. Be sure to include the <Material> start and end
tags.
3. Paste the definition on a new line that follows any material end tag, </Material>.
4. Edit the parameter values to represent the new material being created.

Deleting a Material from the Database
10.2.3 Deleting a Material from the Database
The following steps are necessary to delete an existing entry in the database:
2. Find the <Specification> tag, that contains the name of the material to be deleted.
3. Locate the material start tag, <Material>, directly above the specification tag.
4. Highlight the material definition, being sure to include the material start tag, <Material>, and the
end tag, </Material>.
5. Delete the highlighted material definition.

Changing a Material in the Database
10.2.4 Changing a Material in the Database
The following steps are necessary to modify an existing entry in the database:
2. Find the <Specification> tag that contains the name of the material that will be modified.
3. Locate the parameter tag that will be modified.
4. Change the parameter to the desired value.

Accessing a Different Material Database file
10.2.5 Accessing a Different Material Database file
Note:
#1: Altering the file name will cause Fibersim to improperly access the
database during future Fibersim launches. Make sure the file name
remains unchanged.
#2: When using a network version of the database, you need to check
the DBConfiguration.xml file to find the MaterialDB.xml location.
You can have Fibersim set up to access a different database file (one that is different from
MaterialsDB.xml). This is done by editing the DBConfiguration.xml file. This file is found here:
$FIBERSIM_HOME/FiberSIM/databases
1. Open the file in WordPad or any other text editor program.
2. Locate the <DBFileName> field and enter data so that it points to the full network path of the
database file you want to access.
3. Save the modified file.
Sample section from the DB Configuration file:

How to Edit the Defaults File
10.2.6 How to Edit the Defaults File
To locate and edit the Default file:
1. Locate the file Fibersim_Defaults.xml.
2. Open the file in WordPad, or any other text editor program.
3. Make the necessary changes and save the edited file.
4. Locate and edit FibersimConfig.xml (to make Fibersim_Defaults.xml active).
Note:
Altering the file name can cause Fibersim to improperly access the file
during future launches of the software. Make sure the name of the file
remains unchanged.

Integrating CATMaterials with Fibersim
10.3 Integrating CATMaterials with Fibersim
Fibersim provides the option to use the CATIA V5 CATMaterials database. But in order to use it, several
steps must be accomplished, including customization of the CATMaterials database.
This sections outlines the necessary information for using the CATIA V5 CATMaterials file with Fibersim.
Those choosing to use the CATMaterials database must add various members that are not contained
within the default CATMaterials database.
Note:
You should contact your CAD administrator in regards to customizing

the CATMaterials database with the necessary changes.
Fibersim uses the DBConfiguration.xml file to setup the connection and member mapping from the
CATMaterials database to Fibersim. Member mapping may or may not be necessary depending on the
naming used when customizing the CATMaterials database.
Note:
The CATIA CD3 configuration with products CD1 and ST1 is necessary
since Fibersim uses some of the default CATIA members from the
composite tab of the CATMaterials database. If necessary, you should
contact your CAD administrator to install the additional CATIA
configurations.
In some cases, the Regional settings on your computer may need to be
adjusted to ensure proper operation of the CATMaterials database. You
will need to ensure that numbers use a point (.) as a decimal symbol and
a comma (,) as a digit grouping symbol.
10.3.1 Addition to CATMaterials Database

Addition to CATMaterials Database
All members defined in the Fibersim materials database must exist in the CATMaterials database. This
database does include some of the members that are required for Fibersim. For these members,
Fibersim uses the DBConfiguration.xml file to map the CATMaterial members to the Fibersim members.
You will have to add the remaining members in order for all Fibersim features to properly function.
When setting up the mapping between Fibersim and the CATMaterials database there are two options:
• If the member names used in the Fibersim materials database are maintained in the CATMaterials
database, then no mapping is necessary in the DBConfiguration.xml file.
• If you choose to name the members differently in the CATMaterials database, then the
DBConfiguration.xml mapping must be used.
For the valid values of these material database members, refer to section A.4.
Additional Members Necessary in the CATMaterials Database
• MaterialCode
• MaterialDescription
• MaterialForm
• WeaveAngle
• BoltOrientation
• Units
• LaminateRating
• DropOff
• NonStructural
• Color_0_Degrees
• Color_45_Degrees

Addition to CATMaterials Database
• Color_Other_Angles
• Line_Style_0_Degrees
• Line_Style_Other_Angles
• Line_Thickness_0_Degrees
• Line_Thickness_Other_Angles

CATMaterial Members Used by Fibersim
10.3.2 CATMaterial Members Used by Fibersim
This is a list of the CATMaterial members used by Fibersim.
CATMaterials Name Fibersim Member Name
Name Specification
CompMaxDeformation Warning
CompLimitDeformation Limit
CompUncuredThickness Thickness
CompCuredThickness CuredThickness
CompWidthOfFabrics Width
CompWeightPerSurfaceUnit ArealWeight
CompCostPerMassUnit CostPerWeight
Longitudinal Young Modulus ElasticModulusOne
Transverse Young Modulus ElasticModulusTwo
Poisson Ratio in XY Plane PoissonRatio
Shear Modulus in XY Plane ShearModulus
Longitudinal Thermal Expansion ThermalExpansionOne
Transverse Thermal Expansion ThermalExpansionTwo

CATMaterial Members Used by Fibersim
Fibersim DBConfiguration.xml Mapping
This is a sample setup for setting up the DBConfiguration.xml file for mapping:

Configuring the DBConfiguration.xml file
10.3.3 Configuring the DBConfiguration.xml file
Configuring the DBConfiguration.xml is necessary in order to establish a connection between Fibersim

and the CATMaterials database. There are several ways to make a connection:
1. Connect to a CATMaterials file using a network path.
2. Connect to a CATMaterials file from ENOVIA.
3. Connect to an ‘In Session’ CATMaterials file.
This section will outline how to connect to the CATMaterials database using all three of these methods.
Necessary DBConfiguration.xml Changes
Note:
The line numbers referenced below may change for various reasons. If
confusion arises due to inaccurate line numbers, please contact Siemens
PLM Global Technical Access Center (GTAC).
For each installation of Fibersim:
1. Locate the DBConfiguration.xml file that is located in:
%FIBERSIM_HOME%\FiberSIM\databases
2. Open this file in a text editor, like WordPad or Notepad on Windows.
3. Edit Line Number 3 from:
<DBConfiguration name="material"> to: <DBConfiguration name="hold">
<DBConfiguration name="cad"> to: <DBConfiguration name="material">

Configuring the DBConfiguration.xml file
<DBFileName><![CDATA[C:\My_Materials.CATMaterial]]></DBFileName>
to:
<DBFileName><![CDATA[Path_to_CATMaterial]]></DBFileName> where Path_to_CATMaterial is one

of three choices:
a. For Defining an explicit network path to the database file:
C:\any_dir\name_of_catmaterial_file.CATMaterial
b. For opening a database via ENOVIA:
ENOVIA5\name_of_catmaterial_file.CATMaterial
c. For using an ‘in session’ database. If this method is chosen only one database can be loaded in
session at a time:
In Session
6. Edit Line Number 17:
<DBApplicativeSpecName>My_DB_Spec_Name</DBApplicativeSpecName> My_DB_Spec_Name
should be changed to the name given to the file used to expand the properties in the CATMaterials
database.
7. Save the file.
8. Copy the edited file to all other Fibersim installations.

Materials Database Members
10.4 Materials Database Members
This section lists all members in the materials database with descriptions for each one.

Standard
10.4.1 Standard
MEMBER DESCRIPTION
Standard Tab
Specification Defines material names displayed in Fibersim.
<Specification> Note:
Names must be unique for every material in the database file.
Fibersim synchronizes materials based on names.
Material Code A unique code for each material. Up to 72 characters.
<MaterialCode>
Material A unique description for each material.

Description
<Material
Description>
NCF Orientation Fibersim supports the input of non-crimped fabric (NCF) material
orientations. NCF materials can contain two or more layers of fiber
<NCF Orientation> tows, stitched together. You must specify a single orientation to
represent this material. The NCF orientations can be positive or
negative values.
Note:
To use an NCF material with Fibersim, you need to define the
MaterialForm member as “NCF”:
<MaterialForm>NCF</MaterialForm>
Material Form Material type used by Flat Pattern producibility. Values are:
• Woven for bi-directional materials
• Uni for unidirectional materials
<MaterialForm> • Tow for fiber placement materials
• Film, Mat, or Core for non-fabric materials

Standard
Note:
For a non-fabric material, Fibersim defaults to Woven.
Warning The deformation warning angle for the material used by Flat
Pattern/Producibility. Governs where Fibersim should alert you that
<Warning> the material is being deformed a given amount (yellow fiber paths).
Valid values are in degrees, any real number greater than 0.
Note:
By convention, this value is usually half the limit angle.
Limit The deformation limit angle for the material used by Flat Pattern/
Producibility. This angle specifies the angle after which the material
<Limit> will wrinkle when deformed.
Fibersim uses this information to display red fiber paths on the part
where the material will wrinkle. Valid values are in degrees.
Width Usable width of the material. Fibersim uses this value to determine
material width lines for Plies. Valid values are any real number > 0.
<Width> You must enter values in inches or millimeters.
Units Specifies the unit system for the specific material. All parameters
for a material should be in the same unit system.
<Units>
• English – use Imperial units for the material.
• Metric – use SI units for the chosen material.
Crimp Warning Used with NCF materials.
<CrimpWarning>
Crimp Limit Used with NCF materials.
<CrimpLimit>
Balanced By For balanced materials, this is the material’s balanced pair. For NCF
materials.
<BalancedBy>

Thickness
10.4.2 Thickness
MEMBER DESCRIPTION
Thickness Tab
Specification Defines material names displayed in Fibersim.
<Specification>
Thickness Thickness of the material prior to curing. The Laser Projection

Interface uses this value during data offset.
<Thickness>
Valid values are real numbers > 0. Enter values in inches or

millimeters.
Cured Thickness Thickness of the material after curing. Fibersim uses this value when
calculating the Design Station thickness.
<CuredThickness>
Valid values are any real number > 0. Enter values in inches or
millimeters.
Units Specifies the unit system for the specific material. All parameters for
a material should be in the same unit system.
<Units>
• English – use Imperial units for the chosen material.
• Metric – use SI units for the chosen material.

Architecture
10.4.3 Architecture
MEMBER DESCRIPTION
Architecture Tab
Material Form Material type used by Flat Pattern/Producibility. Values are:
<MaterialForm> • Woven for bi-directional materials
• Uni for unidirectional materials

• Tow for fiber placement materials
• Film, Mat, or Core for non-fabric materials
Note:
For a non-fabric material, Fibersim defaults to Woven.
Drop-Off Specifies whether or not a material will be included in a Zone

Transition drop-off. In some cases a given material needs to be
<DropOff> included in zone definitions, yet excluded from dropping-off.
Values are Yes (included in drop-offs) or No (excluded).
Weave Angle Defines the manufactured angle, in degrees, between the warp and
weft fibers of a fabric material.
<WeaveAngle>
Note:
Currently Fibersim only supports materials with a 90-degree
weave angle.
Bolt Orientation Defines whether a material is woven parallel (0 degrees) or biased

(45 degrees) to the roll direction. Valid values are Parallel or Bias.
<BoltOrientation>
Non–Structural Specifies whether or not a material will be included in the Analysis

export data. Some materials are not included in the structural
<NonStructural> analysis of the composite part, therefore these materials shouldn’t be
output during the exporting of analysis data.
You can define behavior on a material by material basis. Values are

Yes (excluded) or No (included).

Cost & Weight
10.4.4 Cost & Weight
MEMBER DESCRIPTION
Cost & Weight Tab
Areal Weight Weight of the material per unit area. Units must be either lb/in2 for
the English system, or kg/mm2 for the Metric system. Valid values are
<ArealWeight> any real number > 0.
Cost Per Weight Cost of the material per unit weight. Weight must be in the same
units as those used in ArealWeight. Values are any real number > 0.
<CostperWeight>
Units Specifies the unit system for the specific material. All parameters for a
material should be in the same unit system.
<Units>

Laminate Rating
10.4.5 Laminate Rating
MEMBER DESCRIPTION
Laminate Rating Tab
Laminate Rating Determines if a material will be evaluated in a laminate rating core

sample analysis. Options are Yes or No.
<LaminateRating>

Mechanical Properties A
10.4.6 Mechanical Properties A
MEMBER DESCRIPTION
Mechanical Properties A Tab
ShearModulus 1–3 Specifies the shear modulus value in the XZ plane.
<ShearModulusOne
Three>
ShearModulus 2–3 Specifies the shear modulus value in the YZ plane.
<ShearModulusTwo Three>
Density Specifies the real mass density value.
<MassDensity>
Shear Modulus Specifies the shear modulus of the material. Value is used
during Laminate rating Core sample analysis.
<ShearModulus> Units of this entry must be in lb/in2 for the English system
or N/m2 for the Metric system. Values are any real number >
0.
Poisson Ratio Specifies the poisson ratio of the material. Value is used
during a laminate rating core sample analysis. Valid values
are any real number 0 – 1.
<PoissonRatio>
Poisson Ratio 1-3 Specifies the poisson ratio of the material.
Poisson Ratio 2-3 Specifies the poisson ratio of the material.
Elastic Modulus One Elastic or Young’s modulus of the material in the warp
direction. Value is used during a Laminate rating Core
sample analysis.

Mechanical Properties A
Units must be in lb/in2 for the English system or N/m2 for

<ElasticModulusOne> the Metric system. Values are any real number > 0.
Elastic Modulus Two Elastic or Young’s modulus of the material in the weft
direction. Value is used during a Laminate rating Core
sample analysis.
<ElasticModulusTwo>
Units must be in lb/in2 for the English system or N/m2 for
the Metric system. Valid values are any real number > 0.
Elastic Modulus Three
Units Specifies the unit system for the specific material. All
parameters for a material should be in the same unit
<Units> system.

Mechanical Properties B
10.4.7 Mechanical Properties B
MEMBER DESCRIPTION
Mechanical Properties B Tab
Tensile Stress 1 Allowable stresses in the tension (in longitudinal

direction).
<AllowableTensile
StressOne>
Tensile Stress 2 Allowable stresses in the tension (in lateral

direction).
<AllowableTensile
StressTwo>
Compressive Allowable stresses in the compression (in

longitudinal direction).
Stress 1
<AllowableCompressiveStressOne>
Compressive Allowable stresses in the compression (in lateral

direction).
Stress 2
<AllowableCompressiveStressTwo>
Shear Stress Allowable stress for the in-plane shear.
<AllowableShear
Stress>
Tensile Strain 1 Allowable strains in the tension (in longitudinal

direction).
<AllowableTensile
StrainOne>
Tensile Strain 2 Allowable strains in the tension (in lateral direction).
<AllowableTensile

Mechanical Properties B
StrainTwo>
Compressive Allowable strains in the compression (in

longitudinal direction).
Strain 1
<AllowableCompressiveStrainOne>
Compressive Allowable strains in the compression (in lateral

direction).
Strain 2
<AllowableCompressiveStrainTwo>
Shear Strain Allowable strain for the in-plane shear.
<AllowableShearStrain>
Units Specifies the unit system for the specific material.

All parameters for a material should be in the same
<Units> unit system.

Custom MAT8 Properties
10.4.8 Custom MAT8 Properties
MEMBER DESCRIPTION
Custom MAT8 Properties Tab
Structural Damping Coefficient Structural damping coefficient value.
<MAT8Structural
DampingCoefficient>
Tsai-Wu Interaction Term Interaction term (in the tensor polynomial theory of
Tsai-Wu)
<MAT8TsaiWuInteractionTerm>
Stress/Strain Theory For maximum strain theory only. Indicates whether Xt,
Xc,Yt, Yc and S are stress or strain allowables.
<MAT8MaxStrain
Theory>
<Units> system.

Thermal Properties
10.4.9 Thermal Properties
MEMBER DESCRIPTION
Thermal Properties Tab
Thermal Expansion One Specifies the coefficient of thermal expansion in the warp
direction. Value is used during a laminate rating core
<ThermalExpansionOne> sample analysis.
Units must be in Fahrenheit for the English system, Celsius

for the metric system. Values are any real number > 0.
Thermal Expansion Two Specifies the coefficient of thermal expansion in the weft
direction. Value is used during a laminate rating core
<ThermalExpansionTwo> sample analysis.
Units must be in Fahrenheit for the English system, Celsius

for the metric system. Values are any real number > 0.
Thermal Expansion Specifies the reference temperate for the calculation o

Reference Temperature thermal leads, or a temperature-dependent thermal
expansion coefficient.
<ThermalExpansion
ReferenceTemperature>
<Units> system.

Radius of Curvature
10.4.10 Radius of Curvature
MEMBER DESCRIPTION
Radius of Curvature Tab
ROC Warning Desired radius of curvature warning value for the material used by
the simulation steering results display.
<TowROCWarning>
Governs where Fibersim should alert you when the material is

beginning to undergo a radius of curvature below a certain amount
(yellow fiber paths). By convention, it is usually half of the radius of
the curvature limit value.
Value should be in inches or millimeters.
Tow ROC Limit Desired radius of curvature limit value for the material that is used
by the simulation steering results display.
<TowROCLimit>
Governs where Fibersim should alert you that the material is being
steered below the minimum radius of curvature allowed for the
given material (red fiber paths). Value should be in inches or
millimeters.
Units Specifies the unit system for the specific material. All parameters for
a material should be in the same unit system.
<Units>

Orientation Colors
10.4.11 Orientation Colors
MEMBER DESCRIPTION
Orientation Color Tab
These colors defines the outline colors ply boundaries in Ply Books and 3D Cross Sections.
See Chapter 1, section 1.7 for a full list of colors used.
0 Degree Orientation Color Defines the outline color of 0 degree ply boundaries.
<Color_0_Degrees>
45 Degree Orientation Color Defines the outline color of 45 degree ply

boundaries.
<Color_45_Degrees>
90 Degree Orientation Color Defines the outline color of 90 degree ply

boundaries.
<Color_90_Degrees>
–45/135 Degree Orientation Color Defines the outline color of -45 or 135 degree ply
boundaries.
<Color_135_Degrees>
+/–45 Degree Orientation Color Defines the outline color of -45 or +45 degree ply
boundaries.
<Color_np45_Degrees>
0/90 Degree Orientation Color Defines the outline color of 0 or 90 degree ply
boundaries.
<Color_090_Degrees>
Other Degree Orientation Color Defines the outline color of cores and any ply
boundaries that are not 0, 45, -45, 90 or 135
<Color_Other_Angles> degrees.

Line Styles
10.4.12 Line Styles
MEMBER DESCRIPTION
Line Style Tab
These options define the line styles for ply boundaries in Ply Books and 3D Cross Sections.
Options are Solid, Dashed, Dotted and Phantom (combination of dotted and dashed).
0 Degree Orientation Line Style Defines the line style of 0 degree ply boundaries.
<Line_Style_0_Degrees>
45 Degree Orientation Line Style Defines the line style of 45 degree ply
boundaries.
90 Degree Orientation Line Style Defines the line style of 90 degree ply
boundaries.
–45/135 Degree Orientation Line Style Defines the line style of -45 or 135 degree ply
boundaries.
–/+45 Degree Orientation Line Style Defines the line style of -/+45 degree ply
boundaries.
<Line_Style_np45_Degrees>
0/90 Degree Orientation Line Style Defines the line style of 0/90 degree ply
boundaries.
Other Degree Orientation Line Style Defines the outline line style of cores and any ply
boundaries that are not 0, 45, -45, 90 or 135
<Line_Style_Other_Angles> degrees.

Line Thickness
10.4.13 Line Thickness
MEMBER DESCRIPTION
Line Thickness Tab
These options define line thicknesses for ply boundaries in Ply Books and 3D Cross
Sections.
Options are Thin (default), Medium and Thick.
0 Degree Orientation Line Thickness Line thickness of 0 degree ply boundaries.
<Line_Thickness_0_Degrees>
<Line_Thickness_45_
Degrees>
–45/135 Degree Orientation Line Thickness Defines the line thickness of -45 and 135
degree ply boundaries.
<Line_Thickness_135_Degrees> Line thickness of 135 degree ply

boundaries.
+/–45 Degree Orientation Line Thickness Line thickness of +/- 45 degree ply
boundaries.
<Line_Thickness_np45_Degrees>
0/90 Degree Orientation Line Thickness Line thickness of 0/90 degree ply
boundaries.
Other Degree Orientation Line Thickness Defines the outline line thickness of cores
and any ply boundaries that are not 0, 45,
<Line_Thickness_Other_Angles> -45, 90 or 135 degrees.

Custom
10.4.14 Custom
MEMBER DESCRIPTION
Custom
Replace With Define a material, used as an alternative to the

selected material.
<ReplaceWith>
Manufacturer Enter the manufacturer of the material. Optional.
<Manufacturer>
Customized data Enter customized information, and information is

displayed under each column.
(One – Five)
<ColumnNameOne> Values entered here can be output to ply books.
<ColumnNameTwo>
<ColumnNameThree>
<ColumnNameFour>
<ColumnNameFive>

Machine Database Members
10.5 Machine Database Members
This section lists members in the machine database with descriptions for each one.
MEMBER DESCRIPTION
Standard
Name The model or internal name of the machine.
<Name>
Manufacturer Machine manufacturer name
<Manufacturer>
Machine Type Type of automated machine (values are

Automated Tape Layer or Fiber Placement).
<MachineType>
Description Description of the machine and its capabilities.
<Description>
Minimum Course Length Shortest length of a course or tow (minimum

cut length)

<MinCourseLength>
Roller Diameter Diameter of the roller on the head of tape layer

or fiber placement machine.
<RollerDiameter>
Number of Tows Number of tows that the fiber placement head

can deposit.
<TowsPerHead>
Minimum Tape Width Smallest tape course width allowed by the

machine.
<MinTapeWidth>
Minimum Cut Width Smallest tape width that is allowed by the

machine to remain when notched.
<MinCutWidth>
Minimum Across Cut Angle Minimum angle relative to a course centerline

allowed to be cut by the machine
<MinAcrossCutAngle>
MEMBER DESCRIPTION
Tape Parameters
Minimum Course Length Shortest length of a course or tow (minimum

cut length)
<MinCourseLength>
Roller Diameter Diameter of the roller on the head of tape layer

or fiber placement machine.
<RollerDiameter>
Minimum Tape Width Smallest tape course width allowed by the

machine.
<MinTapeWidth>
Minimum Cut Width Smallest tape width that is allowed by the

machine to remain when notched.
<MinCutWidth>
Minimum Across Cut Angle Minimum angle relative to a course centerline

allowed to be cut by the machine
<MinAcrossCutAngle>

MEMBER DESCRIPTION
Fiber Placement Parameters
Max Roller Height Travel Maximum value for the roller height
travel.
<MaxRollerHeight>
Warning Roller Height Travel Warning value for the roller height
travel, prior to it reaching its maximum.
<WarnRollerHeight>
Max Collision Avoidance Angle Maximum value for machine

articulation that avoid contact with the
<MaxCollisionAvoidAngle> work piece.
Warning Collision Avoidance Angle Warning value for machine articulation

that avoid contact with the work piece.
<WarnCollisionAvoidAngle>



11. Index B: Utilities
11.1 Introduction
This chapter discusses the utilities used with the Fibersim product.
Fibersim uses these utilities and tools to verify that design requirements are being met. Ply listing,
sorting, and visualization tools let engineers inspect all aspects of the layup, including material types,
stackup order and orientations.
11.1.1 Accessing the Utilities in Fibersim
Most Fibersim utilities can be accessed from the toolbars that appear with each object window. You can
also access many of them from clicking on Tools on the Encapta menu:

The Main Utilities Toolbar
11.2 The Main Utilities Toolbar
There is a group of utilities that always appear on the object window toolbar, regardless of what object is
currently highlighted:
• Design Checker
• 3D Cross Section
• Composite Sequence Manager
• Object Locator

Design Checker
11.2.1 Design Checker
The Design Checker lets you run checks on the model to search for invalid geometry and current design
problems.
From the “Geometry” tab, when you press Check Geometry, the utility will interrogate the model and
report back any objects that have geometry issues to be resolved. “Flagged” objects will be listed in the
Flagged Objects member.
These objects will also be listed in the “Geometry Report” window, with a description of the problem.
If you select the Extra Geometry Checks option, Fibersim will perform a check on any geometry that is
unintended, but is still valid for the model.

Design Checker
From the “Design” tab, select which boundary you want the utility to run a check on; either Net or
Extended.
When you press Check Design, the utility will interrogate the model and report back any objects that
have design issues to be resolved. “Flagged” objects will be listed in the Flagged Objects member.
These objects will also be listed in the “Design Report” window, with a brief description of the problem.

Design Checker
Detailed Descriptions of Design Checker Functions
OBJECT CHECKS/FUNCTION DETAILS
Laminate Confirm one of the boundaries (NET or EXTENDED) exist.
Validate the origin (confirm it exists and lies on the skin).
Store broken boundaries for display (NET and EXTENDED).
Verify the boundary lies on the skin (NET and EXTENDED).
For Advanced Curvature Mode (ACM) check polycurves for the following
errors:
• "Inconsistent closed status"
• "Inconsistent segment indexing"
• "Segment ends have large gaps"
• "Segment ends have small gaps"
• "Segment ends and tessellation points are inconsistent"
• "Inconsistent segment orientation"
• "One or more segments are too short"
• "Polycurve not linked to skin"
• "Bad normals"

Design Checker
Rosette Check for the following errors:
• "Error when updating rosette."
• "No skin defined."
• "No origin defined."
• "No direction curve defined."
• "Origin is not on skin."

• "Origin is not on direction curve."
• "Direction curve is normal to skin."
• "Rosette has no spoke."
• "Rosette has zero increment angle."

Design Checker
Splice Confirm the parent laminate.

Group
Confirm splice curves.
Confirm the trim boundary.
Confirm you can apply the initial offset.
If overlap distance > 0:
• Check if we have valid topo skin (not corrupted).
• Check if we can get proper direction point (a point on the other side of
the splice curves from the laminate origin, and we have just a single
one)
• Check if we can get proper direction vector for offset.
• Check if we can create geodesic offset for the curves on the skin.
• Validate the offset curves and make sure they can be extended to the
laminate net.

Design Checker
Cutout Confirm you can get the layup surface from the parent.
Validate the origin.
Confirm that cutouts lie within the laminate Net Boundary.

Design Checker
Region Validate the origin.
Confirm the parent can be found.
Confirm the boundary type is valid.
Confirm the parent boundary is valid.
Confirm the boundary is valid:
Check for the following errors:
• "No skin defined"
• "No origin defined"
• "No boundary or parent boundary defined"
• "Boundary curve is not closed"
• "Boundary cannot close to parent boundary"
• "Hole curve is not closed"
• "Origin is not on skin"
• "Origin is inside hole"
• "Could not get the Layup Surface from the Parent"
Check if the boundary is on the parent's layup surface.
Validate holes, checking for errors:
• "Could not get the Layup Surface from the parent"
• "At least one hole is not on the parent's layup surface"

Design Checker
Darts Confirm we can get the skin and the base curve.
Course Check we can get the course boundary.
Validate the origin (check if it exists and lies on the skin).
Check the NET boundary does not overlap the parent boundary.
Store broken boundary for display (NET and EXTENDED).
Verify the polyshape lies on the skin (NET and EXTENDED).
Confirm that holes are closed, doesn't intersect the boundary, is not outside the
boundary, and the origin is not inside any hole. For D2M check that the hole
lies within the parent net boundary.
Validate direction (i.e. it is on the Direction, it can be mapped).

Design Checker
Zone Check if boundary exists and lies on the parent skin.
Validate the origin.
For Advanced Curvature Mode (ACM) check polycurves (same as described in

Laminate).
Validate the parent boundary.
Zone Check if we can get the Parent.

Transition
Check if we can get the parent's Layup Surface.
Check if we can get the Design Boundary
Check if the curve is not outside the laminate boundary.
Check if the number of offset curves corresponds to the target number.

Design Checker
Layer For Advanced Curvature Mode (ACM) validate the plus one boundary.
For Advanced Curvature Mode (ACM) validate the centerline.
Confirm the NET boundary does not overlap the parent boundary.
For NET and EXTENDED holes check if the hole is closed, doesn't intersect the
boundary, is not outside the boundary, and the origin is not inside any hole. For
D2M check that the hole lies within the parent net boundary.

Design Checker
Core Validate the origin (confirm it exists and lies on the skin).
Layer
Store broken boundaries for display (NET and EXTENDED).
Confirm the polyshape lies on the skin (NET and EXTENDED).
boundary, is not outside the boundary, and the origin is not inside any hole.
For D2M check that the hole lies within the parent net boundary.
For variable parametric core check for the following errors:
• "Top Boundary must be set for Virtual Variable Core"
• "Bottom Boundary must be set for Virtual Variable Core if Bottom

Thickness is non-zero. Core Samples and Cross Sections may be
incorrect"
• "Top Holes must be set if holes exist."
• "Bottom Holes must be set if bottom boundary and holes are set."
• "Cannot have a top hole without a Top Boundary."
• "Cannot select more than one Top Boundary."
• "Top Hole curve must be closed."
• "Top Hole is not on the skin."
• "Cannot select a Top Hole without a Top boundary."
• "Variable_core_boundary_polyshape cannot be found."
• "Cannot select a Bottom Hole without a Bottom Boundary."

• "Cannot select more than one Bottom Boundary."
• "Bottom Hole curve must be closed."
• "Bottom Hole is not on the skin."

Design Checker
• "Cannot select a Bottom Hole without a Bottom Boundary."

Design Checker
Ply Check for either NET or EXTENDED boundary.
D2M check that the hole lies within the parent net boundary
Validate the direction (ex: can map the direction; the origin is on the direction)

Design Checker
Core Validate the origin (confirm it exists and lies on the skin).
For NET and EXTENDED holes check if the hole is closed, does not intersect the
D2M check that the hole lies within the parent net boundary.
Confirm we can get the core boundary polyshape:
Validate ribbon direction checking for the following errors:
• "Ribbon Direction has no valid geometry"
• "Ribbon Direction is on core boundary"
• "Ribbon Direction is outside core boundary"
• "Origin is not on ribbon direction curve"

Design Checker
Notes when using "Extra Geometry Checks" option:
OBJECT When "Extra Geometry Checks" option is used:
Laminate Then also check if:
• Polycurve can be tessellated.
• Individual curves do not overlap.
• All curves are part of the boundary.
• All curves do not overlap the parent boundary.
• No duplicated curves for NET or EXTENDED.

• Do the same checks for holes as well.
Cutout Then also check the laminate boundary.
Zone Same as described above for Laminates.
Ply Same as described above for Laminates.
Also check for the following errors:
• "Ply must have a Net Boundary to use darts"
• "Ply must have an Extended Boundary to use Minimum Course

Extensions"
Core Same as described above for Laminates.

Design Checker
About the "Design Check"
Design Runs through plies (NET or EXTENDED based on the option).

Check
Check for the following errors for all plies:
• "Could not get the Parent"
• "Manufacturing Process does not match the laminate's Manufacturing

Process" (laminate's process matches the ply process)
• "Could not get the Automated Deposition Machine from the laminate"
(the parent laminate must have a machine set)
• "Could not get the Material"
• "Manufacturing Process is not compatible with the Material" (the

material type must also match the process)
Check if plies are automatically depositied (AFP/ATL):
If YES (auto_deposited) - detect course challenges and check the following:
• "Minimum course length challenges were detected" (for AFP)
• "Minimum across cut angle challenges were detected" (for ATL)
• "Minimum course length challenges were detected" (for ATL)
If NO (not auto_deposited) - try to detect the following:
• Check the NET or EXTENDED producibility.
• Check if material width is exceeded.
• Check if flat patterns exist and are up-to-date.

Cleanup Utility (NX-specific)
11.2.2 Cleanup Utility (NX-specific)
This menu allows the user to set which options ensure that Fibersim data gets completely removed, or
"cleaned up". You can delete Fibersim objects or move the objects to specific layers. This new dialog is
found in the File menu: File> Utilities> Fibersim Cleanup. (Note that the acronym UDO refers to user-
defined objects.)
"Fibersim Description
Cleanup"
Menu Field
Part Options here are WorkPart, Work Part and Components or All Loaded
Parts.

Cleanup Utility (NX-specific)
Simple Move Fibersim UDOs to Layer – This lets you move Fibersim user-defined
Cleanup objectsto a specific layer, by specifying a Layer Number(entered as a layer
Actions ID). Values are 1-256.
You can also specify the layer using the new element in the
FibersimConfig.xml file. Specifying this element will tell Fibersim which
NX layer on which to create UDOs.
NOTE: You will need to move old user-defined objects to the correct layer,
in thisdialog window, even if this is set in the FibersimConfig.xml file.
Serious Delete Fibersim Data (UDOs) - When this option is checked:

Delete
Actions • If Fibersim is not running, data will be deleted from the parts
Note (Use indicated in the part selection.
Caution)
• If Fibersim is running, it will be suspended, and all relevant parts will
be "unloaded", and data containers (UDOs) stored in the parts will be
deleted.
• If Fibersim isstarted after using cleanup, the part(s) will appear

"clean" as if they have never had any Fibersim data in them. (Normal
save deferral rules will apply.)

Partial Boundary Editor
11.2.3 Partial Boundary Editor
The Partial Boundary Editor helps to speed up the highlighting of layer boundaries.
It allows Fibersim to work with a reduced set of vertices/zone transitions, and then calculate the
boundaries only for this reduced set.

MEMBER DESCRIPTION
Laminate Specify the laminate to be used with the given workgroup.
The choice of laminate determines the Zone Transition and

Transition Adjacency Vertices that can be worked on.
Status Whether or not the given workgroup is valid or invalid.
Workgroups can become invalid when a design change

occurs that adds or removes a zone transition from a
workgroup. Note that using the Zone Transition Splitter can
also result in an invalid workgroup.
Zone Transition Locator
Positions Indicate points on the CAD surface, next to Zone Transitions,

to be located.
Locate Fibersim will locate zone transitions, based on the defined

Position points.
Start Over This option clears the member values for the given
workgroup, which allows for redefining of the workgroup.
Workgroup - Selected Objects
Transitions Provides a list of located Zone Transitions, to be worked with

for the given workgroup.
Using the Zone Transition object list window, you can tiered
edit into Zone Transitions so that they can be manipulated.
Vertices Provides a list of located Transition Adjacency Vertices, to be

worked with for the given workgroup.
Using the Zone Transition object list window, you can tier
edit into Zone Transitions so they can be manipulated.
Affected Displays the list of layers that get affected when Zone
Layers Transitions or Transition Adjacency Vertices for the given
workgroup are edited.

Highlight Highlights the partial boundaries for each layer that is

Layers affected by the given workgroup.

Composite Sequence Manager
11.2.4 Composite Sequence Manager

The Composite Sequence Manager (CSM) allows you to view a laminate’s hierarchy. All components that
have the current laminate as their parent will be shown, including laminates, layers, plies, and cores.
Note also that every shown child component is listed in sequence step order.
Note:
If accessed via a child laminate, Fibersim only displays children of the child laminate.
SPECIAL NOTE: When Sequence Based Projection is turned on the CSM will list any plies
that have been projected as children of the override laminate, as long as that laminate has
been selected as the root laminate. When Sequence Based Projection is turned off, the
CSM shows only the plies that are explicitly parented to that laminate.
Sequence Based Projection is an option on the laminate object.

MEMBER DESCRIPTION
Laminate Select the laminate to be read by the CSM.
Show Child The CSM will display all of the laminate’s child components.
Components
Note:
Child laminates are only listed if they have a different
surface than the parent laminate.
Note:
If layers exist in the model, they are listed by default.
But if child plies exist, this option must be checked to
view them.
Sequence Options (pop-up menu)
Initial Step Defines the initial step value given to the child laminates of
the parent laminate that the resequence is initiated from.
This value is not given to the laminate that the resequence is
based on. You must first change the step value of the
laminate that the resequence is based on.
The first component on the Laminate that the resequence is

based on will be given the same step value as the parent
Laminate. Then child laminates will be given the Initial Step
value, and the child laminates first component will also be
given the Initial Step value. The value entered for the Initial
Step must be an integer.
Step Defines the step value increment for components that are
Increment sequenced via the Composite Sequence Manager resequence
icon. The value entered for the Step Increment must be an
integer.
Maintain The CSM will keep components that were on the same step
Same Step before resequencing on the same step after resequencing.
For example, if you have a ply pack that has 4 plies on step
40, then all four plies will have the same step value after
resequencing.
Resequence Determines what the CSM will resequence:

Mode
• Sequence and Step – resequence both the sequence
and step values.
• Step Only – only resequence the step values and leave

the sequence values as defined by the user. The Step

Increment value increments Step values, and Fibersim

will increment the sequence values alpha numerically.
If the laminate sequence value is A, then child components ill

all have a sequence value of A, and child laminates will have
sequence values incremented alphanumerically (B, C, D…
etc).
Child components of top-level laminates and child laminates

will always be given the same sequence value as their parent
laminate.

Resequence Options
11.2.4.1 Resequence Options
You can create, modify, and delete objects within the CSM. These are the options for globally
resequencing child components of the current laminate:
RESEQUENCE DESCRIPTION
OPTION
Drag and Drop Child components of a laminate can be moved to new

Resequencing locations in the part hierarchy.
When moving objects, Fibersim automatically interpolates

new Step values based on existing steps above and below
the new location. For example, if a ply with step 50 is
moved in between steps 30 and 40, the new step value for
this ply is 35.
Note:
If all child components of a laminate have the same
Step value, Fibersim cannot move objects via the drag
and drop method. You must use the Resequence icon,
which gives unique steps to each component.
When moving layers, Fibersim wants to change the
parent of the ply, which is not valid. You should use
Ctrl+select to select a range of layers individually,
meaning plies will not be selected to move. Since ply
parents cannot be changed, the ply will follow the
layer wherever it goes.
When Show Child Components is checked,
resequencing by drag and drop is disabled.
Manually You can manually resequence child components of the

Resequencing Laminate by editing components and manually entering
new Sequence/Step values.
Resequence The Resequence icon can globally update Sequence/Step

Icon values of child components on the current laminate. This
gives each ply a unique step value (except when a ply is
spliced via a layer). The resulting plies will all inherit the Step
value from the layer.

Resequence Options
Note:
Before using Resequence, you should enter an
appropriate Initial Step and step increment value, and
set the appropriate step values on the parent
laminate.
Resequencing is useful once all laminate components have

been moved to the appropriate location in the part
hierarchy. By default, Fibersim gives the laminate and the
laminate’s first component the same Step value.

Object Locator
11.2.5 Object Locator
The Object Locator lets you locate and highlight several different Fibersim entities. You can highlight
desired objects, and then indicate points next to the objects that Fibersim will locate.
MEMBER DESCRIPTION
Parent The parent laminate of the objects to be located.
Object Type The type of object to populate in Highlighting.
Positions Indicate next to each object that needs to be located.

Object Locator
Locate Performs the location of the objects. The location is based on

the Object Type chosen, and user-indicated points.
Start Over Clears the Highlighting list, populates it based on Object

Type.
Highlighting
Specifies the list of objects that are highlighted. Includes:
• Zones
• Transitions
• Vertices
• Layers
• Core Layers
• Plies
• Cores
Once you indicate points and locate the desired objects,

these lists display the located objects.
Boundary Boundary type for the plies, either Net or Extended.

Type
Refresh Refreshes the highlight list.

Highlight
Highlight Whether objects remain highlighted after exiting the utility:

Scope
• Local – highlighting stays on when Object Locator is
open
• Global – highlighting stays on when you exit the utility.

Tools > Operations
11.3 Tools > Operations
This section contains a list of individual Fibersim utilities and operations:
• Material Substitution
• Mirror Laminate
• Zone to Layer Analysis
• Step Utility
• Drop Off Order Utility
• Ply Drop Off
• Splice Ply
• Grid Based Zone maker
• Zone Transition Splitter
• Minimum Course Extension Utility
• Minimum Course Vertex Utility
• Formed Laminate Utility
• Flat Pattern Layout
• Course Generation Utility

Material Substitution
11.3.1 Material Substitution
This utility lets you substitute materials used for zone based design. During the design process a new
material may be preferred over an existing one. Rather than change all material specifications that
reference the obsolete material, and run a zone to layer update, the Material Substitution utility can be
run.
A zone to layer uses material to match zones and create common layer shapes. Since all previous zone
transitions and layers reference a material that no longer exist, all of the zone transitions and layers get
deleted and new ones are generated. This utility prevents zone transition customization from being lost.
MEMBER DESCRIPTION

Material Substitution
Laminate Laminate on which to perform the substitution.
Old Material The material to be replaced.
New Material The new material to use.
Substitute Material Perform substitution of material specs and layer

materials.

Mirror Laminate
11.3.2 Mirror Laminate
This utility creates “mirrored”, or copied, plies based on a set of existing plies. This is useful when many
identical plies need to be defined. This utility aids in creating a laminate schedule that is balanced,
symmetric, or both balanced and symmetric.
MEMBER DESCRIPTION
Laminate The laminate to be mirrored or copied
Note:
For a top-level laminate, all child plies are also eligible.
For a child ply, only its own children are eligible.
Start The first ply used for mirroring or copying.

Component

Mirror Laminate
End The last ply used for mirroring or copying.

Component
Operation Whether a mirror or copy is conducted on selected plies.
Pivot Specifies whether the end component ply becomes a pivot.

Component
If P005 is selected as a pivot ply, results are:
P001, P002, P003, P004, P005, P004, P003, P002, P001
If no pivot is specified for mirroring, results are:
P001, P002, P003, P004, P005, P005, P004, P003, P002,

P001
If P005 is selected as a pivot ply for copying, results are:
P001, P002, P003, P004, P005, P001, P002, P003, P004
If no pivot is specified for copying, results are:
P001, P002, P003, P004, P005, P001, P002, P003, P004,

P005
New Step Starting step values. Based on how plies are stepped,
Fibersim applies Step values to new plies.

Zone to Layer Analysis
11.3.3 Zone to Layer Analysis
Zone-to-Layer Analysis automatically creates layers and plies from zone definitions. Fibersim matches up
material and orientation across all of the zones, and constructs boundaries.
This utility is also used as an update utility when a design change is necessary. Zone-to-Layer updates
prevent you from losing any customizing that has been done to Zone Transitions and Transition
Adjacency Vertices. The update also maintains any sequencing that has been applied to layers and plies.
When run, Fibersim creates necessary Zone Transitions, Transition Adjacency Vertices, and the resulting
layers/plies. You can customize each as the design requires. Fibersim also provides a report that
describes what objects were created/updated as a result of running the analysis. This report lists any
errors encountered during the analysis. Fibersim also provides a Zone Checker, within the utility.
On parts where many zones are required, user error is likely when selecting zone boundaries. The Zone
Checker will analyze zones, and report if any overlap or void areas exist. If the checker is not used, and
you have made a mistake during zone definition, Zone to Layer Analysis results will be incorrect.

MEMBER DESCRIPTION
Laminate Specifies the laminate(s) to be processed during the

analysis.
Offset This offset specification will be assigned to newly created

Specification transitions.
Stagger Profile Stagger Profile to be applied to all Zone Transition objects,

created as a result of running the Zone to Layer Analysis.
Fibersim will only apply selected Stagger Profiles to any

existing Zone Transitions. You can leave this member
blank, and manually apply Stagger Profiles to each Zone
Transition.
Run Zone Runs the Zone Checker only. Verifies that the geometrical
Checker Only Zone setup is correct. Also checks for improperly defined
and overlapping zones.
Generate Generate or update plies/layers of the created zone

transitions.
Update Options
Result Type Whether the analysis will create Layers or Layers and Plies.
Since layers drive plies, you could create the plies via the Layer
object as a final step.
Delete... By checking the right boxes, you can delete obsolete layers,
plies, transitions or vertices.
Fibersim deletes these objects during the Zone to Layer update.
Note:
In most cases, you will want all options selected.
Run Zone Whether or not Fibersim will run the Zone Checker when the
Checker analysis is run. The Zone Checker verifies that the geometrical

with Zone setup is correct. It also checks for improperly defined and
Analysis overlapping zones.

Step Utility
11.3.4 Step Utility
The Step Utility applies Step values based on layer areas. Layers that cover the largest area will be
furthest from the laminate centerline. Layers that cover the smallest area will be closest.
This utility properly places non-overlapping layers of the same material and orientation on the same
Step. This provides a starting point, that is easily adjusted based on your requirements.
Note that Step values can be adjusted, or you can use the Preliminary Design Interface to export a data
file to Excel®. You can then change Step values and import the changes back into Fibersim.

Step Utility
MEMBER DESCRIPTION
Laminate The utility works on a laminate-by-laminate basis, so child

laminates must be processed separately.
Material Material used for assigning new Step values.
Note:
If a laminate contains multiple materials, you must run
the utility separately for each material.
Orientation Specifies the repeating Orientation used when assigning Step

Pattern values to layers. Fibersim uses user-input patterns as a guide
when assigning Step values through the thickness of the part.
The orientation list should be comma-separated values.

Default pattern is 0,45,90,-45.
Initial Step Defines the initial step value given to the first layer. Must be a
Value valid integer value. Default is 10.
Step Defines the Step increment added first to the Initial Step
Increment value, and then to each subsequent layer’s Step value.
Layers are given values starting at 10 and incrementally

increased by 10, resulting in 10, 20, 30, 40…etc. This value
must be a valid integer value. Default is 10.

Drop-Off Order Utility
11.3.5 Drop-Off Order Utility
This utility assigns drop-off order values to layers for a given material. After running, you can adjust the
values as necessary. The Drop-Off Order specifies how a laminate’s layers are dropped off from the
thickest gage areas to the thinnest.
Fibersim uses the Drop-Off order when associating Zone Transition index curves to corresponding
Layers.
Note:
It is recommended setting Drop-Off Order Pre-Sorting, in the Laminate

form, to “No Pre-Sorting”.
This utility applies Drop-Off Order values based on Laminate Spec and layer area information. Layers that
use the largest number of Laminate Specs, and cover the largest area are given larger Drop-Off Order
values. The number of Laminate Specs for a given layer takes precedence over the layer’s area.
In many composite designs, disjoined overlapping pieces of composite fabric (of the same material and
orientation) exist at the same step in the stackup. These pieces or plies should be treated as if they were
all one continuous piece of material, meaning layers/plies should have the same step value and Drop-Off
Order. This utility assigns Drop-Orders for this condition.

Drop-Off Order Utility
MEMBER DESCRIPTION
Laminate Specifies the laminate. (Child laminates must be processed

separately.)
Material Specifies material for assigning new Drop-Off Order values. If a

laminate contains multiple materials, you must run the utility
separately for each.
Orientation Orientation repeat pattern, for non-drop-off plies.

Repeat Pattern
Initial Drop-Off Defines the initial Drop-Off Order value given to the first layer. Must
Order be a valid integer.
Drop-Off Order Defines the Drop-Off Order increment added first to the Initial Drop-
Increment Off Order value, then to each subsequent layer’s Drop-Off Order
value. Layers’ values start at 10 and increase incrementally by 10
(10, 20, …etc.) Must be a valid integer.

Ply Drop-Off
11.3.6 Ply Drop-Off
The Ply Drop-Off utility creates smooth transitions, along boundaries of pad-up of plies.
MEMBER DESCRIPTION
Plies Plies that are to be dropped-off. Must all share the same
boundary.

Ply Drop-Off
Plies per The number of plies to be included in each drop-off.

Drop Off
Boundary Determines where Ply Drop-Offs will be created:

Type
• Net Boundary or Extended Boundary specify that Drop-
Offs create along the respective boundary.
• Net Holes or Extended Holes specify that Drop-Offs create

along every hole in the ply.
Note:
Dropping-off both the boundary and the holes is a two-
step process, that can be done consecutively.
Geometry Specify either Boundary or Holes.

Type
Direction Determines the direction in which drop-offs will be created.
• Inside – Drop-offs occur toward the ply origin
• Outside – Drop-offs occur away from the ply origin
Offset Based Whether the offset distance is based on:

On
• Distance – distance between Drop-Off curves.
• Material Thickness – Drop-Off curve offset distance is

based on multiplying thickness of the chosen material by
this value.
Corner Type The corner type to be applied to generated Drop-Off curves.

Options are Straight, Chamfer and Fillet.
Fibersim only applies a chamfer or a fillet to inside corners. The

fillet radius and chamfer distance is determined by, and will
vary by, the offset distance. The chamfer angle is always set to
45°.
MEMBER DESCRIPTION

Ply Drop-Off
Drop-Off Plies are dropped off in an Ascending, Descending or a user-

Pattern defined Custom order.
Custom Displays a custom sequence in which the plies will be

Drop-Off dropped-off. Beginning with 0 and incrementing by 1, the
Sequence sequence number corresponds with plies in the order they
were chosen from ply list.
For example, if you define the sequence 0,3,4,2,1 for plies

P001, P002, P003, P004, P005, the drop off order will be:
P001, P004, P005, P003, P002
Note:
Used when Drop-Off Pattern is set to “Custom”.

Splice Ply
11.3.7 Splice Ply
The Splice Ply utility lets you splice selected plies based on predefined boundaries. In many cases, a
fullbody ply may not meet design standards, for reasons such as unacceptable fiber deviation, or
because the material width cannot accommodate for the size of the laminate.
This utility is useful in these scenarios, since multiple plies can be generated in one quick step.
USAGE REQUIREMENT: The ply's origin point must be between the laminate
net boundary and the first splice curves. Also, the splice curves must be selected
in order.

Splice Ply
MEMBER DESCRIPTION
Ply The ply to be spliced. Remember that the plies’ origin must
be in between the first splice curve and the Net Boundary.
Splice Curves Curves to be used as splice boundaries. Curves must lie on

the laminate and both ends should intersect the specified
ply boundary. The curves must be selected in order.
Note:
Splice curves will be created away from the origin
point.
Overlap Specifies whether spliced plies overlap.
Distance Spliced ply overlap distance (toward the ply origin).
Flip Overlap Flip the direction of the splice overlap.

Direction
No Splice Regios where splices should not be performed.

Regions
Toggle Region Turn on/off display of No Splice Regions.

Display
Ply Name Separator character to use.

Separator

Grid-Based Zone Maker
11.3.8 Grid-Based Zone Maker
This utility creates a set of zones, based on inputting a set of curves and origin points.
This is useful on grid based parts that have horizontal and vertical grid lines with an origin point inside
of each bay. Fibersim will create zones based on the order that the origin points are selected or
indicated.
MEMBER DESCRIPTION
Laminate The parent laminate of the created zones.

Grid-Based Zone Maker
Rosette The rosette used for the created zones.
Indicate You can select and un-select points that are picked using the
Origins digitization process. This means that you can pick a ply origin
and it will use the laminate surface as the support
automatically (existing point is turned on as well). You can
also trap select existing points.
Note that the order in which the points are indicated is the
order in which Fibersim creates zones.
Boundary Curves to create Zone Boundaries. Fibersim creates zone

Curves boundaries based on closing selected curves around selected
origins.
Use Names When checked, zones will be generated and given the same
from Origins name as their origin.

Zone Transition Splitter
11.3.9 Zone Transition Splitter
In many cases the initial set of defined zones are based on stress data and the part’s substructure. Zone
transitions will then be computed based on the inputted zones. In some cases a large zone boundary
may need to represent several zone transitions, and you may need to go back and redefine zone setups.
The Zone Transition Splitter allows zone transitions to be split based on a ratio, non-tangency, curve,
points, or distance along the transition. Once run, Fibersim will create additional zone transitions and
apply them to the appropriate layers.
MEMBER DESCRIPTION
Zone Transition The transition to be split.
Splitting Methods
Ratio Length ratio for splitting.
Non-Tangency Angle Non-tangency angle for splitting.
Curves or Points Curves or points at which to split the transitions.

Zone Transition Splitter
Distance Split transition at this distance.
Repeat Splitting Repeats splitting of split transitions at specified

distance.

11.3.10 Minimum Course Extension Utility
SPECIAL NOTE: Each of these utilities is discussed in Chapter 6.

11.3.11 Minimum Course Vertex Utility
SPECIAL NOTE: Each of these utilities is discussed in Chapter 6.

Formed Laminate Utility
11.3.12 Formed Laminate Utility
The Formed Laminate utility allows you to run a simulation that incorporates linterlaminar sliding, due
to thickness of the material and the different layers conforming to the part surface.
With this utility, you can document a relationship between a given laminate and its plies, when the
laminate represents a “formed laminate” part. (Note that a formed laminate part is a composite part
made of a single mat composed of several layers of the same material, each with its own orientation,
held together by fibers stitched through the thickness of the laminate.)
The utility outputs a series of stitch length contours, which are displayed based on the stitch length
being some multiple of the laminate thickness. The image below shows the results of running the
composite producibility on a model:
Note how the stitch length is changing, as the laminate is draped on the part surface. This utility can
assist you with where stitches should be placed in 2D, such that the necessary change in length for 3D is
minimal.

The utility can also create a flat pattern that represents the maximum (or minimum) material condition
for the formed laminate. This is done by overlaying the flat patterns and intersecting them to create the
formed laminate flat pattern.
To open the utility, go to Tools > Operations > Formed Laminate Utility.
Select the proper radio button of either the Net or Extended boundary, for which you want to run the
utility.
MEMBER DESCRIPTION
Laminate Select a laminate for forming.
Contour Spacing This value is the stitch length as some multiple of the
laminate thickness. Contours will display based on this
value.

For example if the laminate is 1mm thick and you enter a

value of “2” here, a contour will be created each time a set
of points has stitches that are twice the laminate
thickness.
Warning The stitch length warning value. This will determine the
blue/yellow/orange/red coloring of the contours in the
CAD window.
Limit The stitch length error limit value. This will determine the
blue/yellow/orange/red coloring of the contours in the
CAD window.
Composite Runs the simulation and generates the producibility of the

Producibility formed laminate.
Formed Flat Pattern
Creation Method Select an option to determine how the composite flat

pattern should be created:
• Max - Created by the union of maximum flat pattern

shapes
• Min - Created by the union of minimum flat pattern

shapes
Composite Flat Generates the composite flat pattern

Pattern
Stitch Report
Spacing X Controls the stitch report sampling density in the X-

direction, where X is based on the flat pattern zero
direction.
Spacing Y Controls the stitch report sampling density in the Y-

direction, where Y is orthogonal to the X-direction.
Stitch Report File Specify the stitch report file.
Stitch Report Indicate the points on the surface that you want to show
Points up in the stitch report.
Note:
This will override the normal behavior of the stitch
report if this member is set.
Generate Stitch Generates the stitch report in the window.

Report

The report will always be in millimeters.

Flat Pattern Layout
11.3.13 Flat Pattern Layout
This utility allows you to manipulate how flat patterns display in the CAD window. By setting the
parameters, such as cell width/height values and origin coordinates, you can ensure that the flat
patterns properly display in the CAD window in a grid fashion.
SPECIAL NOTE: This utility is discussed in detail in Chapter 7.

Course Generation Utility
11.3.14 Course Generation Utility
This utility allows you to generate courses on a given layer. The utility takes a layer and a starting
centerline, and is used to progressively generate course objects starting there, and moving out to the
part edges.
This utility runs a simulation out from a given centerline, out to the material width on each side. The
centerline may be the layer's centerline or an adjacent course centerline, computed from a given course
lying on a layer.
MEMBER DESCRIPTION

Course Generation Utility
Layer Specify the layer on which you want to generate courses.
Centerline Centerline of the layer. Must be specified to generate

courses.
Material Material that makes up the layer.
Overlap This value is the overlap distance between a course, and

any adjacent courses.
Fiber Spacing This value controls simulation cell size. A default of 1.0 is
Factor usually sufficient for an accurate simulation, and to
generate an accurate flat pattern.
Generate Course Creates the course, which consist of a centerline,

boundary and material/step information from the layer.
Generate Right/ Check these options and can you select a material for the
Left Adjacent adjacent courses.
Centerline
Left/Right Select the material for the right/left adjacent course.

Adjacent Course
Material
Courses Displays a list of generated courses.
Report Displays a report of the course creation actions.

Tools > Derivative Laminates
11.4 Tools > Derivative Laminates
This section includes a list of tools used for special laminate creation:
• Symmetric Laminate
• Merge Models
• Surface Transfer
• Manufacturing Laminate Creation
• 2D Laminate Creation

Symmetric Laminate
11.4.1 Symmetric Laminate
The Symmetric Laminate utility creates a duplicate dataset of a laminate, by mirroring information about
a symmetry plane. This is useful when creating left and right parts that are symmetric about a given
plane.
To use the utility:
You must mirror the laminate surface and boundaries manually, as well as the rosette origin/direction.
Note also that valid laminate and rosette objects must be created in Fibersim prior to running the utility.
This utility will duplicate the geometry associated to the laminate and rosette objects.

Symmetric Laminate
MEMBER DESCRIPTION
Source Laminate The laminate whose components will be mirrored. Child laminates
are not carried over by this utility (each one needs to be
generated separately).
Source Rosette The rosette for the source laminate data.
Symmetric The destination laminate that source information will be copied

Laminate to.
NOTE: This must be an actual laminate that has already been

created, prior to running the utility.
Symmetric Rosette The rosette for the symmetric laminate data.
NOTE: This must be an actual rosette that has already been

created, prior to running the utility.
Symmetry Plane The plane in the part file. Components will be generated on the
other side of this plane.
Options
Delete Existing Deletes all existing components before generating new ones.
Components
Delete Obsolete Deletes any components that are no longer being used.
Components

Merge Models
11.4.2 Merge Models
The Merge Models utility merges together matching zone-based layers on adjacent segments of a part
that has been split up to allow for concurrent design. Before merging the segments back together, the
following requirements should be met:
• Ensure Sequence, Step, and Drop-Off order is set in all segment models.
• Ensure that layers that merge across segments are collinear at edge of the segments.
• Part segments should not overlap, or have a gap at the split lines.
• Adjoining segments should all meet at the same split line.
It is recommended using Merge Model in an assembly that contains the part segment files and the part
that will contain the results of the merging.
You should create Result Boundary Features for the layers before using the Merge Model utility. (This
can reduce Merge Model running time.)

Merge Models
MEMBER DESCRIPTION
Source The laminates whose layers are to be merged.

Laminates
Merged Laminate that merged Layers will be created on.

Laminate
Note:
The appropriate Net Boundary and laminate surface
must be set up. The Net Boundary should be
equivalent to merging together the Laminate Net
Boundaries from part segments.
Merged Rosette Rosette for the merged part. (The rosette must already exist
before Merge Models is run.)
Delete Existing Deletes layers that already exist in the merged part.
Layers

Surface Transfer
11.4.3 Surface Transfer
The Surface Transfer utility transfers project layers or plies from one laminate to another. This is useful
when the initial design may have been done on an OML surface and then needs to be transferred to the
IML (or vice versa). This utility is also useful to transfer layers from an under core surface to an over core
surface.
MEMBER DESCRIPTION
Source Laminate Laminate that the layers or plies are being transferred
from.

Surface Transfer
Source Rosette Specify the source rosette.
Target Laminate Laminate that layers or plies are being transferred to.
Target Rosette The rosette for the part that will contain the transferred
layers or plies.
Options
Transfer Method Specifies the method when transferring layers or plies:
• Direction – uses the surface normal from the From

Laminate and pushes the layers/plies over to the new
surface.
• Offset-Projection – first offsets all Layers/Plies into

3D space based on the surface normal of the From
Laminate, then uses the surface normal of To
Laminate to pull Layers/Plies over to the new surface.
Object Type Specifies whether Fibersim will transfer Layers or Plies.
Reverse Step When you have designed on the OML, and need to
Values transfer to the IML, it is often necessary to invert Step
values. This option inverts Step values when transferring
layers or plies to the new laminate.
Delete Existing Deletes all existing layers/components before generating

Component new ones.
Delete Obsolete Deletes any layers/components that are no longer being

Components used.
Collinear Angle Angle that determines when Fibersim will consider two
adjoining line segments collinear. When encountering two
line segments that have a collinear angle equal to or less
than this value, Fibersim considers the segments collinear.
In most cases, default of 5 degrees is sufficient. Values are

0 – 15.

Manufacturing Laminate Creation
11.4.4 Manufacturing Laminate Creation
The Manufacturing Laminate Creation utility lets you create a manufacturing dataset (a “child”) from an
engineering dataset (the “parent”). The “parent” is then linked to the “child” dataset and can be updated
as necessary.
Note:
If parent datasets change, rerun this utility, and Fibersim will update the
children.
Ply data will transfer to the new laminate so that a new simulation can be run.

MEMBER DESCRIPTION
Engineering Laminate The engineering (or original) laminate that will

provide the data for the new laminate.
NOTE: Child laminates are not carried over.
Engineering Rosette The rosette for the engineering laminate data.
Manufacturing Laminate The manufacturing (or destination) laminate.

(The laminate must already exist.)
Manufacturing Rosette The rosette for manufacturing laminate data.

(Rosette must already exist.)
Options
Type The component type at which to stop, either

Layer or Ply.
Delete Existing Fibersim will delete all child components and

Components create new ones.
NOTE: No updates are run on the child dataset.
Delete Obsolete When a change to the parent dataset involves

Components deleting a component, you will most likely want
the same component deleted in the child. This
option ensures this happens.
Last Component - Controls the last component used for Manufacturing

Laminate Creation. The Manufacturing Laminate will be created up to the
selected layer or ply.
Last Layer Provides access to the layer list.
Last Ply Provides access to the ply list.

Springback
These options let you specify the new manufacturing laminate. Ply data will transfer to the new
laminate so that a new simulation can be run.
SPECIAL NOTE: When running with Springback, the Manufacturing Laminate

created must not have a net or extended boundary. It must be physically larger
than the engineering laminate. If the Manufacturing Laminate has a net or
extended boundary defined, Fibersim will generate these automatically upon
running the utility.
MEMBER DESCRIPTION
Engineering Boundary for the simulation to map to the springback

Simulation Laminate. Should be larger than the Net Boundary, to
Boundary ensure transfer of boundaries to the springback laminate.
Springback Boundary for the simulation, to map from the

Simulation engineering laminate. Should be larger than the Net
Boundary Boundary, to ensure the simulation can transfer
boundaries from the engineering laminate.
Fiber Spacing Accepts a value 0.01 – 10. Controls mapping simulation

factor cell size. Default value is 1.
Propagation Choose the propagation method. Either Standard,

Method Geodesic, To Curve or About Curve.
Constraint Curve Curve used as a constraint, for the To Curve or About

Curve propagation methods.
Propagation Choose a Propagation Direction, either Parallel, Bias

Direction (-45), Bias (+45) or Orthogonal.
First Stage Region Select a boundary curve, to define the first region in
which the Multi-Stage simulation will run.

2D Laminate Creation
11.4.5 2D Laminate Creation
This utility allows you to create a 2D representation of the 3D laminate, by flattening the 3D laminate
data to a 2D laminate. The 2D laminate makes the generation of laser projection data much easier.
MEMBER DESCRIPTION
3D Laminate The original 3D laminate, provides data for the new

laminate.

2D Laminate Creation
3D Rosette Specifies the reference rosette for the 3D Laminate.
3D Simulation Simulation boundary of the 3D Laminate. Should select

Boundary a slightly bigger boundary than the laminate Net
Boundary.
2D Laminate The new 2D Laminate, receives information from the

3D Laminate.
Note:
This laminate must be already created.
2D Rosette Specifies the reference rosette for the 2D Laminate.
Options
Delete Existing Fibersim deletes all child components and creates new
Components ones.
Note:
No updates are run on the child dataset.
Delete Obsolete When a change to the parent dataset involves deleting

Components a component, you will most likely want the same
component deleted in the child. This option ensures
this happens.
Use Plies’ Flat Use existing flat patterns as boundaries of the 2D plies.
Patterns

Tools > Curve Creation
11.5 Tools > Curve Creation
This section includes a list of individual utilities for manipulating curves.
• Fiber Path Curve Creation
• Curve Creation
• IML Curve Creation
• Boundary Simplification
• Curve Offset

Fiber Path Curve Creation
11.5.1 Fiber Path Curve Creation
The Fiber Path Curve Creation utility lets you create curves after receiving producibility results. Red lines
in the model will show fiber deviations that are out of spec. This utility lets you make geometry to
contain the deviations.
These created curves can then be added to a part’s Net Boundary.
MEMBER DESCRIPTION
Note:
For a top-level laminate, all child components are
eligible for Fiber Path Curve Creation. For child
laminates, only its own children are eligible.

Fiber Path Curve Creation
Ply Specify the ply, to show its producibility.
Update Ply Updates the selected ply producibility.

Producibility
Fiber Path Specifies the fiber path along which a new curve will be
Position created.
Once producibility has been run on the selected ply,

indicate a point beside the desired fiber path.
Generate Generates the curve along the selected fiber path.

Curve Creation
11.5.2 Curve Creation
The Curve Creation utility creates curves and boundary geometry based on user-input points. Select or
indicate points on a desired surface, and Fibersim will fit a curve through these points.
This utility is handy when you need to quickly create a curve, perhaps to add a virtual core on top of a
ply.
Curves can then be used for boundaries, section cuts, or any other purpose that necessitates curve
creation.
MEMBER DESCRIPTION
Surface Surface on which the curve lies.
Points to Points used to create the resulting curve. Points can be

Connect selected or indicated.

Curve Creation
Note:
The order that points are selected/indicated determines
the order in which Fibersim fits a curve through the
points.
Close Curve Whether Fibersim will close the curve or leave the curve
open-ended.
Generate Generates the curve on the surface, from the selected points.

IML Curve Creation
11.5.3 IML Curve Creation
The IML Curve Creation utility creates a set of boundary curves (IML curves), based on the laminate
thickness at each layer boundary in the part.
MEMBER DESCRIPTION
Laminate Select a parent laminate.
Boundary Type IML Curves are created based on Net or Extended

Boundaries.

IML Curve Creation
Laminate Surface Select the component type for the laminate surface,
Component Type either Layers, Plies, or Layers & Plies.
Layers The layers to use to generate IML Curves.
Note:
When Laminate Surface Component Type is set to
“Layer” or “Layer & Ply.”
Plies Plies used to generate IML Curves.
Note:
When Laminate Surface Component Type is set to
“Layer” or “Layer & Ply.”
Options
Internal Boundary Whether Fibersim will create closed curves for each IML
Curves Only curve (No), or an open curve that breaks against the Net/
Extended boundary (Yes).
Remove Minimum Remove minimum course vertices from the layer

Course Vertices boundary.

Boundary Simplification
11.5.4 Boundary Simplification
The Boundary Simplification utility creates CAD geometry from component and zone boundaries. This
helps create organized curves from each component’s definition. Curves can be closed curves, or curves
that break to the laminate boundary.
Note:
It is recommended using curves that break against the laminate

boundary. This utility lets you associate created geometry back to
Fibersim objects.
Fibersim-generated curves will be overridden by curves created from
this utility.

MEMBER DESCRIPTION
Note:
For a top-level laminate, all child components are
eligible for Boundary Simplification. For a child laminate,
only its own children are eligible.
Boundary Determines boundary type generated by this utility:

Type
• Net – curves based on Net boundary.
• Extended – curves based on Extended boundary.
• Net & Extended – curves based on Net & Extended

boundaries.
Plies List of eligible plies.
Zones List of eligible zones. Zones are determined by the parent

laminate.
Layers Layers to be exported.
Options
Associate Whether Fibersim will associate the created curves back to

Geometry Fibersim components.
Note:
Use caution before associating this data back to objects.
If original curves are parametrically defined to handle
updates, this behavior is lost if these curves associate
back to Fibersim.
Internal Whether Fibersim will create closed curves, or curves that

Boundary break against the Laminate’s Net/Extended boundary.
Curves Only
Note:
If curves will define plies/layers, it is recommended to set
this to Yes. We do not recommend using closed curves
for ply/layer definitions, unless plies/layers are multi-
domain.

Match “Yes” means that Fibersim tries to create the boundary curves
Existing based on pre-existing curves in a model.
Curves
Non- Curve non-tangencies with an angle equal to or greater than

Tangency the specified angle will be maintained in the result curve.
Angle
• Lower the angle if the desired non-tangencies are being
smoothed out.
• Increase the angle if the result curve becomes too

facetted.

Curve Offset
11.5.5 Curve Offset
In composite design, often times a series of similar curves need to be generated at a constant distance,
or offset, away from each other. Most common cases are where a pad-up of plies are located on a part,
or where a zone-to-zone thickness transition requires a smooth drop-off of plies.
Since these pad-ups and thickness transitions may require the creation of many curves over complex
surfaces, it can be time-consuming and problematic. The Curve Offset utility quickly generates 3D offset
curves on the laminate surface, with a base curve input and offset rules.
There are two types of curve generations available:
• Constant Offset type generates curves at a constant distance in all directions away from the base
curve.
• Directional Offset type is used when a different offset distance is desired in the 0° and 90°
directions, relative to a selected rosette.

Curve Offset
MEMBER DESCRIPTION
Surface Surface on which the offset curves are to be generated.
Curves to The base curve(s) from which offset curves are created. Selected curves
Offset must be chainable, with respect to each other and on the surface.

Curve Offset
Direction Determines the direction when the offset curves are created:
Point
• For a point on the inside of the base curve, curves generate
inward.
• For a curve on the outside of the base curve, curves generate

outward.
Number of Specifies the desired number of offset curves.

Curves
Boundary Curves on the surface, that define the bounds of the offset generation.
Curves Generated curves will be trimmed to the boundary curves.
Curves must be closed and chainable with respect to each other, and on
the surface.
Offest Based Determines what the offset distance is based on:

On
• Distance – distance the curves are offset, in model units.
• Material Thickness – value is based on multiplying thickness of

the chosen material by the Offset Value. You must specify a
Material.
Offset Value Specifies distance or value between generated curves.
Note:
Used when Offset Value Based On is set to “Distance.”
Corner Type Determines the corner type to apply to generated curves. Either
Straight, Chamfer or Fillet. Arrows indicate the direction that the offset
curves were created in.
Note how Fibersim only applies chamfers or fillets to inside corners.

Fillet radius and chamfer distance is determined by, and varies by, the
offset distance.
Chamfer angle is always set to 45°.
Multiple of The distance or value between the generated curves. The distance is the
Thickness result of multiplying the cured thickness of the chosen material and the
value entered here.

Curve Offset
NOTE: When Offset Value Based On is set to “Material Thickness”.
Offset Value Specifies distance or value between generated curves.
Note:
Used when Offset Value Based On is set to “Distance.”
Output Curve Create the output curves as either a construction output curve, or a
Type result output curve.

Curve Offset
Directional Offset
Directional Offsets are used when a different offset distance is desired in the 0° and 90° directions
relative to a selected rosette.
MEMBER DESCRIPTION
Curves to Base curve or curves from which the offset curves are to be
Offset created. Curves must be chainable with respect to each other,
and on the surface.
Direction Determines the direction for the offset curves. For a point on
Point the inside of the base curve, curves generate inward. For a
curve on the outside, curves generate outward.
Number of Desired number of offset curves.

Curves
Rosette At generation of offset curves, the offset direction of a given

part is compared to the rosette’s 0° and 90° directions.
If the offset direction is closer to the 0° direction, the 0°

Offset Value offsets that part of the curve. If closer to the 90°
direction, the 90° Offset Value is used.
Surface The surface on which the offset curves are to be generated.
Boundary Curves on the surface, which define bounds of the offset

Curves generation. Curves are trimmed to boundary curves, and
must be closed and chainable.
Non-Tangency Whether adjoining curves are treated individually or as one

Angle curve. Wherever a non-tangency is present, curves that chain
at that non-tangency are treated as individual curves. Each
curve is treated separately, when Fibersim determines to use
the 0 degree or the 90 degree offset value.
When the curves chain together and a non-tangency is not

present, curves are treated as a whole when determining the
offset value, so all curves are offset the same amount.
The image below shows how the non-tangency angle

determines the varying distance of the resultant offset
curves. (Values between 30 and 60 degrees are
recommended.) If the non-tangency between adjoining

Curve Offset
curves is greater than 60, then curves should be offset

individually.
Offset Value Based On - Distance
Offset Value Determines whether offset value is based on:

Based On
• Distance – distance the curves are offset in model
units.
• Material Thickness – curve offset distance is based on

multiplying the chosen material thickness by this value.
You must specify a Material.
( 0 Degree) Distance or value between generated curves, in 0 degree

Offset Value direction.
Note:
When Offset Value Based On is set to “Distance”.
( 90 Degree) Distance or value between the generated curves, in 90

Offset Value degree direction.
Note:
When Offset Value Based On is set to “Distance”.
Offset Value Based On - Material Thickness
Material Material (from database) to determine the offset distance of

the curves.
Note:
When Offset Value Based On is set to “Material
Thickness”.
(0 Degree) Distance or value between generated curves in the 90 degree

Multiple of direction. Distance is the result of multiplying the cured
Thickness thickness of the material, and this value.
Note:
Thickness”.
(90 Degree) Distance or value between generated curves, in 0 degree

Multiple of direction.
Thickness

Curve Offset
Note:
Thickness”.
The non-tangency between the input curves is 55°. If you specify a 60° non-tangent angle, all curves will
be treated as one entity and no directionality will be applied to the offset.
But, if you specify a 50° non-tangent angle, curves will be treated as separate entities and a directional
offset will be performed.

Tools > Surface/Solid Creation
11.6 Tools > Surface/Solid Creation
This section includes utilities used to create and manipulate surfaces and solids.
• Parametric Surface Offset
• Constant Surface Offset
• Explicit Surface Offset
• Ply-Based Explicit Surface Offset
• Section-Based Surface Offset
• Parameter Thickness Location
• Zone-Based Solid
• Stepped Solid

Parametric Surface Offset
11.6.1 Parametric Surface Offset
The parametric surface offset behaves in a similar manner to the explicit surface offset, with the
exception being how the data is output in the CAD system.
The parametric surface offset uses a constant region curve generated by Fibersim to drive a surface split
and offset in the CAD system. This provides you with a fall back approach if Fibersim generates an
undesirable constant region. The data structure for the parametric surface offset allows you to override
the surface split with a modified curve, which will then update the offset surface parametrically in the
CAD system.

MEMBER DESCRIPTION
Laminate The parent laminate to offset.
Status Whether the surface feature is out of date.
Boundary Type Specifies whether the Surface Offset will be generated

based on Net boundaries or Extended boundaries.
Update Method
Sets the strategy The options are:

for replacing
geometry when a • Replace Surfaces - Regenerates all geometry,
PSO is re-run: replaces the result surfaces, and deletes the old
wireframe (default)
• No Replace - Regenerates all geometry, while

replacing none
SPECIAL NOTE (NX): On the NX CAD platform, there will

not be any support for replacing surfaces. As such, when
using NX, this field will be set as read-only, and
automatically set to "No Replace". Please note that ramps
will not replace. Each time you run a PSO or a PSO with
ramps in NX, the old result will be deleted and a new
result is created.
On CATIA v5, Fibersim will support the replacing of

surfaces.
Ramp Generation
Check this option to ensure that the PSO ramps get created when the PSO utility
is run.
Invert RAMP When the PSO ramps are created, checking this option
Sections and will invert the locations of the sections and guides on the
Guides ramp loft surfaces.
Invert RAIL When the PSO utility is run, checking this option will
Sections and invert the locations of the sections and guides on the rail
Guides swept offset curves.
Create Solid to When generating results, this option lets you generate a
Net solid (not just an IML) from the composite model. You can
generate a solid feature trimmed to the net boundary
after the PSO surface is generated. When this option is
checked, the boundary type is set to "Extended" and
made read-only.

• If the PSO surface fails to complete or has gaps

between the constant regions and ramps, Fibersim
stops and generates an error message. Users will
have to fix the surface and manually create the
solid.
• If this option to is checked when the PSO object
already has an up-to-date PSO surface object, a solid
feature will be created off the existing surfaces. It
will not re-run PSO surface generation.
Options
Last Component The last component in the laminate to offset. Fibersim

generates explicit results up to this last component.
Crossing Layers Sometimes layers that are made up of the same zones
and zone transitions cross one another. This option
enables Fibersim to handle this condition.
Minus-One Offset Trims back constant gage surfaces, by one offset

distance.
Overwrite This option ensures that thickness values will be

Thickness Value overwritten when Generate is pressed.

Constant Surface Offset
11.6.2 Constant Surface Offset
This utility allows you to offset a region or an entire laminate surface by a specified amount. This is
useful for offsetting constant thickness areas of a composite part that can then be sewn together into a
continuous surface. You can offset the desired region by the distance reported by a Fibersim core
sample.
MEMBER DESCRIPTION
Laminate The laminate to offset.

Status Whether the surface feature is out of date.
Create Surface Whether or not to create an offset surface boundary.

Boundary
Boundary Specifies whether the Constant Surface Offset will be

Type generated based on Net Boundaries or Extended Boundaries.
Region Type The type of region to generate the Constant Surface Offset.
• Surface – a Region Surface surface. Default uses the

laminate surface.
• Curves – a Region Boundary Curve. Default is the

laminate boundary.
Region The region surface for the Constant Surface Offset. Default
Surface uses the laminate surface.
Note:
When this is smaller than the surface, Fibersim only
offsets data for the chosen region.
Region Region boundary curves for the Constant Surface Offset.

Boundary Default is the laminate boundary.
Curves
Note:
When curves are smaller than the boundary, Fibersim
only offsets data for the chosen region.
Offset Specifies whether the Offset Thickness is based on:

Thickness
Based On • Value – enter a value in Offset Thickness
• Core Sample – select a Design Station
Offset Specifies the Offset Thickness.

Thickness
Design Station Specifies the Design Station to obtain a laminate thickness.

This thickness is the distance that Fibersim offsets the
Constant Surface.
Generate Whether Fibersim will output a Surface or Solid.
Options (pop-up menu)

MEMBER DESCRIPTION
Material Specifies whether the Constant Surface Offset will be

Thickness generated based on the Cured or Nominal material thickness.
Type
• Cured – create based on Cured material thickness
values.
• Nominal – create based on Nominal or uncured

material thickness.
Note:
When Offset Thickness Based On is set to “Core
Sample”.
Result Type Whether Fibersim will output a Surface or Solid.
Allowance Whether Thickness Variation Allowance will be based on:

Type
• Absolute – input an Absolute Allowance Value
• Percentage – input a Relative Allowance Value
Absolute Absolute allowance thickness added to the Constant Surface

Allowance Offset.
Value

Note:
When Allowance Type is set to “Absolute”.
Relative Specifies the percentage of the Offset Thickness.

Allowance
Value Note:
When Allowance Type is set to “Percentage”.
Heal Offset When enabled, Fibersim attempts to heal surface gaps that
result from offsetting.

Explicit Surface Offset
11.6.3 Explicit Surface Offset
The Explicit Surface Offset utility creates an offset for each constant thickness area of a composite part.
The constant thickness areas generated by this function are offset to the correct thickness based on all
layers.
Using the generated constant thickness regions, you can then model the ramp areas as desired. Once
the ramp areas are modeled and filleted, the result is a very accurate and small data size IML surface.
Since this utility replicates the surface topology of the parent laminate, the surface quality of the Explicit
Offset is sufficient for tooling purposes.

MEMBER DESCRIPTION
Laminate The laminate used for the Explicit Surface Offset.

Choose more than one, as long as laminates are
parented to each other.
Status The status of the Explicit Offset surface.
Boundary Type Explicit Offset results will be generated based on:
• Net Boundaries
• Extended Boundaries
Ramp Generation
These options allow you to create ramps, as well as select the type of ramp
geometry to use in creation.
Ramp Geometry Type These options are active when Ramp Generation is
checked. Select the option to use for ramp geometry
construction:
• Rule Surface – Ruled surfaces work well for

parts that don't need a high level of accuracy
for layer or core ramps.
• Free Form – Free Form ramps use underlying

surface topology of the parent surface when
constructing ramp surfaces. (More accurate in
regards to the true ramp shape.)
Constant Gage Creates constant gage construction boundaries, on

Boundaries the laminate surface.
Options
Last Component The last component in the laminate to offset.

Fibersim generates explicit results up to this last
component.
Offset Region Select a region for outputting Explicit Surface results.

Curves must form a closed loop.
Note:
Fibersim only outputs results for the defined
region.

Break Boundary at When this option is enabled, Fibersim will segment

Curvature the constant gage boundary curves at locations
Discontinuities where the curvature is discontinuous.
Crossing Layers Sometimes layers that are made up of the same

zones and zone transitions cross one another. This
option enables Fibersim to handle this condition.
Minus-One Offset Trims back constant gage surfaces, by one offset

distance.
Heal Offset When enabled, Fibersim attempts to heal surface

gaps that result from offsetting.
Constant Gage Boundaries (pop-up menu)
Internal Curves Only This option means that only curves will be generated
that are not shared by the Net/Extended boundary.
Minus-One Offset This option trims back constant gage surfaces, by

one offset distance.
Error Checker Checks for any potential layer problems. (Results

display in the “Report” tab.)

Ply-Based Explicit Surface Offset
11.6.4 Ply-Based Explicit Surface Offset
This utility allows you to generate explicit surface results for ply based designs. You identify the constant
thickness areas using digitized points or Design Stations, and then Fibersim uses ply data to calculate the
proper offset thickness.

Ply-Based Explicit Surface Offset
MEMBER DESCRIPTION
Laminate Laminate for the offset. You can select more than one
laminate as long as they are parented to each other.
Status Whether ply-based explicit surface object is up to date or

not.
Boundary Type Whether the Ply-Based Explicit Offset is generated based

on Net or Extended boundaries.
Constant Area
Constant Gage Select or indicate origin points to represent the location

Origins of each constant gage region.
Design Stations Select design stations that represent where the constant
regions are.
Toggle Ply Display Toggles on and off the display of all ply boundaries.
Options
Last Component Specify the last component.
Region Boundary Select a region for outputting Explicit Surface results.

Curves Curves must form a closed loop.
Note:
Fibersim only outputs results for the defined
region.
Constant Gage Outputs a boundary curve for each constant gage

Boundaries surface.
Fibersim will output a point at each non-tangency in the

constant gage surface and boundary curves split at each
of these non-tangencies.
Joined Surface Generates the joined surface.
Heal Offset When this is enabled, Fibersim attempts to heal surface

gaps that result from offsetting.

Section-Based Surface Offset
11.6.5 Section-Based Surface Offset
Ply-based parts with crossing boundaries can have complex IML surfaces. It is important to have
accurate IMLs, for mating regions. This utility allows you to create smooth IML section curves, through
which you can loft the offset surface.
Note also that relative surface accuracy can be controlled by the number/position of the section curves,
as well as the spacing of control points. To use this utility:
1. Define section curves on the laminate surface to be projected into 3D space. Fibersim creates IML
curves from the section curves.
2. The CAD system is used to loft a surface through the offset sections.
3. Specify number of points per section curve and the distance between points.
Find the utility here: Tools > Surface/Solid Creation > Section-based Surface Offset

Section-Based Surface Offset
MEMBER DESCRIPTION
Laminate Parent laminate for the offset.
Last Component Specify the last component.
Section Curves Select the curves, to create smooth IML section

curves, through which you can loft the offset
surface.
Curve Point Spacing – Points per Curve
This option forces each section curve to use the same number of points (i.e. a
short curve will have a tighter spacing than a long curve).
Number of Points Specify the number of offset points, for the

creation of IML surfaces.
Curve Point Spacing – Fixed Distance
Distance Between Points Defines the spacing of points along each section
curve, to control the density (and the accuracy) of
the IML curves.

Parameter Thickness Location
11.6.6 Parameter Thickness Location
This object lets you produce a CAD thickness parameter via a Design Station. This parameter represents
the constant thickness areas, and can be used to drive the surface offset distance. This parameter can
also be added to the CATIA spec tree.
Each Parameter Thickness Location object manages the parameter link for each Design Station/Zone
location.
Note:
When a Design Station is updated, the parameters also update.
MEMBER DESCRIPTION

Parameter Thickness Location
Laminate References the parent laminate.
Design Station The design station or zone providing the thickness at this
location.
Start Component Specify starting component for limiting design station results.
End Component Specify ending component for limiting design station results.
Excluded The components selected here will be excluded from the

Components thickness calculation, at this location.
Parameter CAD parameter to specify the thickness value.
Thickness The thickness value, at this location.
Status Thickness parameter is out-of-date or up-to-date.

Zone Based Solid
11.6.7 Zone Based Solid
The Zone Based Solid utility allows you to create a solid based on composite data entered for zone
definitions. Zone boundaries and laminate specification data are used to create the Zone Based Solid.
MEMBER DESCRIPTION
Laminate Specifies the laminate that the Zone Based Solid is based on.
Note:
Child laminates are not automatically inherited for this
utility.
Match Zone Uses the existing CAD curves that represent the zones, when
Boundary splitting the laminate surface and creating the solid.
Curves
• Unselected = Fibersim tessellates the Zone curves and
uses the tessellated geometry for splitting the Laminate
surface and creating the solid.

Zone Based Solid
• Selected = Fibersim uses the existing CAD curves to split

the Laminate surface and create the solid.
Note:
Use only if default behavior fails to create the desired
solid.
Generate Generates the solid.
Status Provides a status for the zone-based solid. Fibersim displays ‘Up
to Date’ if the solid is current per the zone definitions.

Stepped Solid
11.6.8 Stepped Solid
Based on a ply-based explicit, Fibersim lets you generate a step solid for plies (a unioned solid of the ply
stack up). This solid will reflect ply build ups and approximate ramp areas. This provides insight into
geometric problem areas, during composite layup.
The new utility is here: Tools > Surface/Solid Creation > Stepped Solid
1. Once you have a ply stack-up (with or without core), create a new Stepped Solid object.
2. Select a Laminate, boundary type, and a last component, if it is applicable.
3. 3. Click Generate Solid.

Stepped Solid
MEMBER DESCRIPTION
Status Indicates whether the solid feature is up-to-date or out-of-date.
Boundary Type Select either a Net or Extended boundary type for the offset.
Last Component Specify the last component in the laminate, to include in the
solid.
Match Existing Check this option, and solid construction curves will be created by
Curve matching existing boundary curves.

Stepped Solid

Stepped Solid

12. Index C: Tools > Options > Fibersim
Options
12.1 Introduction
These options let you set options that will apply to Fibersim globally. Access these members by clicking
on Tools > Options > Fibersim Options.

Display Colors
12.2 Display Colors
These options turn highlighting on and off, only when an object is in list view (not when an object is in
edit mode).
During edits, highlighting is context sensitive and is always on. Only the Net Geometry and Extended
Geometry views will show/highlight results like the producibility and flat patterns. The other views will
show object definitions (i.e. boundaries, origins), but no results will be displayed.
MEMBER DESCRIPTION
Display Colors
Use Material/Orientation Use the specified color, line type or line thickness
Color indicated in the material database for Core, Core Layer,
Layers & Plies.
Failed Boundary Color This color will highlight failed boundaries.
Failed Boundary Endpoint This color will display the endpoints of failed boundaries
Color in a layer.
First Stage Region Color This color will highlight first stage regions.
Region Highlight Color Controls highlighting color for regions.

Components
12.3 C.3 Naming Conventions
12.3.1 Components
The behavior of the Splice Group functionality for naming conventions works as follows:
After reaching the final letter (“Z”), the convention is now that the next series of splices will be “AA, AB,
AC”, etc. So, if the first 26 splice plies are named (A thru Z) then the 27th would be named as “AA, AB”,
and so on.
You can set the Name Spliced Plies Alphabetically option to set this condition.
MEMBER DESCRIPTION
Name Spliced Plies When enabled, Fibersim will follow the “AA, AB,
Alphabetically AC”, naming convention after the A-Z indexes are
used up.
Disallowed Characters Enter characters that should not be used when

naming Fibersim objects.
Apply Naming The "Disallowed Characters" will be applied to the

Conventions to objects here.

Geometry
12.3.2 Geometry
This feature allows for geometries to be named after their parent. Previous behavior meant that CATIA-
created geometry could be created as a series of un-named items in a geometry set.
When the Name geometry after parent feature option is enabled, geometry is named after the
geometry set.
Example: If the geometry set is called "P001_Boundary", the geometry in that set is named
"P001_Boundary.1", "P001_Boundary.2", etc. This allows you to search for and find the geometry by
name.
Note:
This option was previously only available on NX. Remember that in NX
there are groups instead of geometry sets.
No renaming takes place when you create a geometry set feature for an
already existing group.

Zone Text Display
12.4 Zone Text Display
These options turn highlighting on and off, only when an object is in list view (not when an object is in
edit mode).
MEMBER DESCRIPTION
Zone Text Display
Zone Name Display the zone name, once the zone is highlighted.
Zone Actual Thickness Display the zone’s actual thickness value, once the zone
is highlighted.
Zone Actual Ply Count Display the zone’s actual ply count, once the zone is
highlighted.
Zone Laminate Display the zone’s laminate specification, once the zone
Specification is highlighted.
Text Separator Text separator character.

Flat Pattern Placement Options
12.5 Flat Pattern Placement Options
These options let you choose the location and orientation of Fibersim-generated flat patterns. Fibersim
will orient the ply’s fiber direction on the placement plane based on the Orientation field, under the Net/
Extended Placement Parameters.
Fibersim will also match up the flat pattern origin and the placement plane origin. As a result, flat
pattern origins will be placed at the placement plane origin, which are characteristic of CAD system
created planes.
How CAD systems define the origin of the planes varies for each CAD system. As long as you provide
valid input for the placement plane and orientation, Fibersim will always correctly generate flat patterns
on the selected planes, no matter how the flat patterns look relative to the tool surface.
Note:
Once flat patterns are generated you should not alter the placement plane. If it is altered, be sure
to regenerate flat patterns to ensure they are oriented correctly.

Flat Patterns Tab
12.5.1 Flat Patterns Tab
MEMBER DESCRIPTION
Net Placement - define a placement plane and orientation for Net flat
patterns. If no plane or orientation is chosen, Fibersim uses the model’s XY
plane as the default placement plane, and the X direction as the default
orientation.
Plane Defines the plane that the net flat patterns will be
placed on. Choose a geometric plane that is defined in
the CAD system.
Orientation Orientation of the Net flat patterns on the net

placement plane.
If a plane is chosen for the orientation then the

orientation direction will be the line that is formed from
the intersection of the placement and orientation
planes. Flat patterns will be oriented based on the

Flat Patterns Tab
positive direction of the line formed from the

intersection of the two planes.
Note:
Planes should not be parallel. They need to form
an intersection.
Extended Placement - define a placement plane and orientation for Extended

flat patterns. If no plane or orientation is chosen, Net Placement options are
inherited.
Plane Defines the plane that the extended flat patterns will be
placed on. Choose a geometric plane that is defined in
the CAD system.
Orientation Orientation of Extended flat patterns, on the extended

placement plane.
The orientation direction will be the line that is formed

from the intersection of the placement plane and the
orientation plane. The flat pattern will then be oriented
based on the positive direction of the line formed from
the intersection of the two planes.
NOTE: Planes should not be parallel. They need to form

an intersection.
Orient Flat Specifies whether flat patterns will be oriented by Fiber

Patterns By Direction or by Zero-Degree Direction. (Default is the
Fiber Direction option).
• Fiber Direction - rotates the flat patterns based on

orientation, which ensures the flat patters will be
cut correctly.
• Zero-Degree Direction - orient all flat patterns in

2D as if they were all zero degree plies. (Only used
for visualization purposes, and should not be used
to generate flat patterns for automated cutting
systems.)

Tolerances Tab
12.5.2 Tolerances Tab
Tessellation tolerances affect how Fibersim tessellates a 3D curve. In limited cases, these tolerances may
have to be adjusted in order for Fibersim to process a 3D curve in an appropriate manner.
MEMBER DESCRIPTION
Tolerance Whether Fibersim will use Automatic (default values) or

Setting User-customized tessellation tolerances.
Note:
It is recommended using Automatic. In limited cases
these tolerances may have to be adjusted for Fibersim
to process a 3D curve in an appropriate manner.
Chord Defines the maximum allowable chord tolerance used by

Tolerance Fibersim’s 3D curve tessellation. It defines the maximum
distance, in terms of the chord height of an arc that is

Tolerances Tab
acceptable when tessellating non-straight parts of a 3D ply

boundary.
Lowering the tolerance results in a finer tessellation of 3D

curve boundaries in non-straight sections. Increasing
tolerances results in a coarser tessellation of 3D curve
boundaries in non-straight sections. In general, the default
value for is optimized for Fibersim. In limited cases this
tolerance may have to be adjusted in order for Fibersim to
process a 3D curve in an appropriate manner.
The valid range of tolerance values is from 0.1524 – 14.986

mm or 0.006 - 0.59 inch. The default is 0.3 mm or .012 inch.
Coincidence This tolerance is used as a basis for determining if geometric

Tolerance items are touching one another or if points are identical. (The
chord tolerance is also based off this tolerance.) This is
automatically generated by Fibersim, but can be overridden.
This tolerance must be greater than or equal to the CAD

model's distance tolerance. Decreasing the tolerance will
cause Fibersim to generate more data to represent curves
and/or surfaces. Increasing the tolerance will cause Fibersim
to generate less data for curves and surface tessellations.
Note that a looser tolerance can be specified for parts that are
large and tighter tolerances for smaller parts.
Constant This value controls the tolerance that Fibersim uses when
Gage Overlap computing constant gage regions for surface offset utilities.
Tolerance See section b) below for details.
Factor
Curve Offset This value controls the tolerance that drives point density.
Accuracy See section c) below for details.
Factor
Non- Defines the maximum angle of a non-tangency in a 3D

Tangency boundary curve that will be preserved. Fibersim will not
Angle preserve a non-tangency between two adjoining curve
segments if the non-tangency is below the specified non-
tangency angle.
Conversely, Fibersim will preserve a non-tangency between

two adjoining curve segments if the non-tangency is above
the specified non-tangency angle. Valid range of non-
tangency angles is from 5 to 60 degrees. Default is 15
degrees.

Tolerances Tab
Actual This is the computed value based on the Constant Gage

Tolerance Overlap Tolerance Factor value.
Curve On This option allows you to turn Fibersim’s on surface validation

Surface feature on and off. When enabled, Fibersim will check user-
selected boundary curves to validate whether or not they are
on the laminate surface. When disabled, Fibersim will not
perform this check.
SPECIAL NOTE: This option is not used when advanced

curvature mode is used.
Advanced See sections a1) and a2) below for details.

Curvature
Mode

a1) Upgrade Curve Accuracy (Advanced Curvature Mode)
12.5.2.1 a1) Upgrade Curve Accuracy (Advanced Curvature Mode)
All new parts in Fibersim should be designed using advanced curvature mode, so this option will be
checked by default.
This upgrade feature allows you to upgrade the model to use the Fibersim curve accuracy. It includes a
design check that validates that all boundaries entered in Fibersim adhere to the new tolerances. The
check includes, laminates, plies, cores, core layers, layers, zones, regions, cutouts, etc.
After running the check, Fibersim displays on the screen where there is a gap or overlap in the current
boundaries, when they are selected in the report.
Using the information in the report, you should fix any CAD curves that do not follow the enhanced
tolerances, and link them to Fibersim as needed.
SPECIAL NOTE: This feature means that the entire model will use the enhanced
curve accuracy. This is permanent.
After performing upgrades you must save the model, close it, and reopen it. The
Design Checker runs automatically to report any problems with existing
boundaries.
Usability Notes: Pre-14 parts that have not been upgraded will continue
working in compatibility mode. But pre-14 parts will still have the option to be
upgraded.

a2) Benefits of ACEE Advanced Curvature Mode
12.5.2.2 a2) Benefits of ACEE Advanced Curvature Mode
Advanced curvature mode allows Fibersim to create high quality CAD curves that can then be leveraged
for subsequent behaviors. One of the largest advantages is the use of advanced curvature mode with
the Parametric Surface Offset utility. This utility creates a high quality on surface curve and then
leverages the CAD API's for splitting and offsetting surfaces. This approach provides several benefits:
• High quality constant region curves result in high quality surfaces that can be used for undercore,
overcore, sacrificial and IML surface creation.
• Leveraging CAD API's for splitting and offsetting allows for the offsetting of complex surfaces. For
example, creating offsets of overcore surfaces to get the final IML surface. Intermediate surfaces,
such as overcore surfaces, tend to have complicated topology due to core ramps and fillets. Using
the CAD APIs provides a robust way of offsetting these surfaces. If these offsets fail, there is
generally a fundamental problem with the surface that needs to be fixed. This approach also makes
it possible to offset stringer, beam and other substructure type surfaces, which can be very
challenging due to the complex topology.
• Partial results still provide much benefit to the surface creation process. If a curve generated by
Fibersim is not well formed, you can override the curve and then update the CAD split and offset
operations. The generation of composite part surfaces is a complicated process, so it is prudent to
support partial results that bring value to the process.
Advanced curvature mode also provides benefits to the general creation of CAD curve data in all areas of
Fibersim. The exception is any data created from plies. Plies use lower accuracy representations so
resulting CAD curves will not be as clean. Advanced curvature benefits the following data when driven
from these representations:
• Constant gage boundaries for Parametric Surface Offset.
• Result curve features for layers
• IML curve generation for layers
• Boundary Simplification for layers.
• Derivative Laminate curve generation for layers

a2) Benefits of ACEE Advanced Curvature Mode
PLEASE NOTE: Explicit Surface Offset (ESO) does not fully use advance
curvature mode, so ESO results will not be of the high quality like the PSO.
Parametric Surface Offset was specifically developed to leverage advanced
curvature mode.

b) Constant Gauge Overlap Tolerance Factor
12.5.2.3 b) Constant Gauge Overlap Tolerance Factor

This value controls the tolerance that Fibersim uses when computing constant gage regions for surface
offset utilities.
The default will be adequate for most cases. In some cases, slivers may end up where layers shapes are
not positioned such that the plus-one of one layer matches the ramp of another layer shape, as seen in
the image below. In most cases this should be corrected by proper transition positioning. When this is
not possible, this factor can be increased.

c) Curve Offset Accuracy Factor
12.5.2.4 c) Curve Offset Accuracy Factor
This value controls the tolerance that drives point density. In most cases, the more points that are used
leads to more accurate curve representations. This factor should be reduced if cases arise that need
increased curve refinement.
• If you increase the factor - In general, this will reduce the number of points used for curve
creation. This tends to decrease computation time for operations that offset curves. But usually
increasing the factor leads to a less accurate curve representation. But for cases where the
definition can be captured with a coarse point representation this is not true.
• If you decrease the factor - In general, this will increase the number of points used for curve
creation. This tends to increase computation time for operations that offset curves. Usually
decreasing the factor leads to a more accurate curve representation. But for cases where the
definition can be captured with a coarse point representation, this is not true.

Release Management Tab
12.5.3 Release Management Tab
Fibersim includes special Release Management functionality. This functionality helps ensure that your
data is “locked” when storing the model.
This is useful when you require a complete set of geometry to release the part. By locking down the
model, layer/ply boundary definitions become read only, and you can control editing of the model.
In general, all objects that modify or create new components (i.e. laminates, plies, cores, layers) or
modify the composite part definition (i.e. modify or create flat patterns, surface offsets) become read-
only. Objects used for verification, documentation or export of the composite part definition can still be
modified or created.
Checking the Released Part option will generate features for objects that compute their boundaries
dynamically, and make read-only all the members of all objects that control the definition of the
composite part.

Release Management Tab
This helps to ensure that layer/ply boundary definitions become read only, and remain as is, when
Fibersim is upgraded.
Note:
Upon unselecting this option, and un-releasing the part, Fibersim will
make members non-read-only as appropriate, and if the CAD geometry
has changed since the part was released, will also set the corresponding
features, cross-sections, DSs, surface offsets, etc. to “out-of-date”.
MEMBER DESCRIPTION
Released Signifies that the layer\ply boundary definitions should be

Part locked at this time.
By checking Released Part, Fibersim will generate features for

objects that compute their boundaries dynamically, and make
read-only all the members of all objects that control the
definition of the composite part.
Details of the released part will also be displayed in the

Report.
Feature Angle tolerance to be used when generating features.

Angle
Tolerance
Release User-entered comments and notes.

Notes
Report Fibersim will make members non-read-only as appropriate,

and if the CAD geometry has changed since the part was
released, will also set the corresponding features, cross-
sections, DSs, surface offsets, etc. “out-of-date”.

Index
Fibersim User Guide Index-1

Siemens Industry Software
Headquarters Europe
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About Siemens PLM Software

© 2018 Siemens Product Lifecycle
Siemens PLM Software, a business unit of
Management Software Inc. Siemens, the
the Siemens Industry Automation Division,
Siemens logo and SIMATIC IT are registered
is a leading global provider of product
trademarks of Siemens AG. Camstar, D-
lifecycle management (PLM) software and
Cubed, Femap, Fibersim, Geolus, I-deas, JT,
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FibersimTM User

Chapter 2: Basic (Functions and Interfaces)

Fibersim User Guide 2

Virtual Step Cores ─────────────────────────────────────── 2-53

Fibersim User Guide 3

Construction Transition ────────────────────────────────── 3-47

Chapter 4: Wind (Interfaces)

4 Fibersim User Guide

f) Cutout ────────────────────────────────────────── 4-11

Chapter 5: Automated Deposition Design (ADD)

Chapter 7: Parametric Surface Offset (PSO) Elements

Fibersim User Guide 5

PSO Constant Area ───────────────────────────────────── 7-5

6 Fibersim User Guide

Defining Reference Points ──────────────────────────────── 8-76

Chapter 9: Volume Fill

Index A: Materials and Machine Databases

Fibersim User Guide 7

8 Fibersim User Guide

Manufacturing Laminate Creation ───────────────────────────── 11-68

Index C: Tools > Options > Fibersim Options

Fibersim User Guide 9

10 Fibersim User Guide

As part of a special repackaging project, Fibersim has been divided into a 3-

The product consists of three different packages:

Current CEE licenses will be transitioned to Pro.

Fibersim User Guide 1-1

Current ACEE licenses will be transitioned to Elite.

1-2 Fibersim User Guide

1.2 List of Fibersim packages

PACKAGE INCLUDED SECTIONS IN THIS GUIDE

Base Allows ply-based modeling only.

• Chapters 2 (Base objects) and 7 (documentation) include the objects in

• Chapters 2 (Base objects) and 3 (advanced) are included objects in the

• Chapters 6 (ADD), 7 (documentation) and 8 (PSO) are also included

• Every chapter of this guide discusses elements included in a standard

Fibersim User Guide 1-3

1.3 About the Bundle values

1-4 Fibersim User Guide

1.4 User Guide Breakdown

This is how this user guide breaks down.

SECTION DESCRIPTION CHAPTER

Basic Descriptions of all interfaces under the 2

Advanced Descriptions of all interfaces under the 3

Wind Blade Uses ply-based design for the production of 4

ADD Provides design tools that aid those who use 5

NOTE: ADD tools work with the Pro & Elite

Documentation Special documentation that helps you to 6

NOTE: Special license required for 2D

PSO The PSO section on the application browser 7

Import/Export For importing/exporting composite part data 8

Fibersim User Guide 1-5

SPECIAL NOTE: Each of these interfaces is

Machine & All Fibersim data is communicated using Index A

Utilities Utilities available for all aspects of Fibersim. Index B

Options Tools > Options > Fibersim Options Index C

1-6 Fibersim User Guide

1.5 About the Fibersim Icons

Link with Link Dialog Button

Opens a window containing a list of objects you can select

Opens a link to one of the Fibersim databases.

Allows you to select and link to some element of the model,

For saving report or display results to a file.

For printing reports or display results.