Carbon fiber-reinforced plastics (CFRP) have a great lightweight potential due to their high strength-to-weight ratio. However, new challenges arise due to complex production processes and the large number of design parameters that are subject to variations. This study advances simulation methodologies to address these challenges by modeling the entire CFRP production process while accounting for fiber angle variations at each step. The approach enables prediction of assembly stresses and deformations by utilizing surrogate models, and supports further approaches, such as tolerance optimization and process refinement. Two case studies demonstrate the effectiveness of the method and illustrate its potential to support the optimization of the production process.
