Simulation & Virtual Analysis

At the heart of what we do is a commitment to the continuous development of innovative, advanced composites products and components.

The experts in materials and polymer science at work are more than the brains behind our operation. With a passion for innovation and the drive to see our customers and products succeed. Prazastinav Compositech Pvt Limited (PCPL) has made significant investments in its people and equipment to provide a comprehensive, customizable mix of research, development, and testing services capable of meeting the specific needs of each customer.

When existing methods aren’t good enough, or where a customer has developed an internal method, we will work with our customer to clarify, prove, document, and implement new working procedures or protocols to suit.

Prazastinav Compositech Pvt Limited (PCPL) has considerable experience in the development, analysis and manufacture of novel composite materials. We are skilled in traditional methods of fabricating composite materials as well as the development of cutting edge manufacturing processes for composites.

Some Key Take Away

1. Integrated R&D programs for the development of new composite applications, materials, processes, and designs.
2.  Analysis methods development including critical assessment and validation of analysis approaches and failure criteria.
3.  Material/structural behaviour studies and advanced data analysis, such as characterization of notched strength by detailed material failure mechanisms.

Composite materials in engineering are gaining popularity with manufacturers due, in part, to their lightweight properties, strength, and durability. As with any industrial part or product, composites components must reach quality requirements and go through extensive testing to meet certification requirements, which usually happens late in the development cycle. When defects are found at this stage, they lead to additional time and costs and a delay in getting the product to market. Prazastinav Compositech Pvt Limited (PCPL) uses different simulation software that helps target defects early in the composite product’s development cycle, when it’s easier to fine-tune the manufacturing process. With Prazastinav Compositech Pvt Limited (PCPL),

Prazastinav Compositech Pvt Limited (PCPL) addresses a wide range of composite materials, with a focus on continuous fibres. It can model carbon or glass fibres, thermoset or thermoplastic matrix, dry textiles or pre-pregs

Our innovative simulation techniques helps to target defects early in your composite product’s development cycle, when it’s easier to fine-tune the manufacturing process. The extensive solution capabilities in composites help to analyse and enhance complex composite designs.

Almost all our advanced composite products at the prototyping stage are software simulated to predict their manufacturability using the composite manufacturing process of the need. In fact we use Composite Manufacturing Simulation to predict the manufacturability of all critical products we manufacture

This enables us to choose, design and tweak the composite manufacturing setup optimally - to get the prototype "First Time Right" - from the manufacturing perspective. This also enables us to "understand" the "art" of manufacturing High Performance Composites. Conversion of this "Understanding" into practical improvements in the composite manufacturing and design process is what helps us to constantly be on the cutting edge of Advanced Composite Manufacturing Technology.

• Analyse and optimize individual manufacturing operations


• Link these operations by transferring material history from one operation to the next (change in Fibre orientations, curing degree, temperature distribution)


• Correct, optimize or validate processes like draping, thermoforming, RTM, infusion or curing and etc, to minimize manufacturing defects, insure reproducibility, and decrease development costs

Many composite components require draping of multiple plies over curved surfaces which could lead to material shearing, excessive stretching and a marked change of Fibre orientation. Excessive shearing can lead to manufacturing difficulties, and if the Fibres deviate considerably from the desired orientation, it could lead to a compromised structure

Prazastinav Compositech Pvt Limited (PCPL) simulation techniques deal with the mentioned problem by helping predict the Fibre orientations and shear of unidirectional and woven plies as they drape around curved and complex surfaces and study the behaviour of composite structures across the loading spectrum. Both linear and nonlinear analysis are conducted to predict the response of these structures accurately.

1. Linear and Nonlinear Static
2. Linear and Nonlinear Transient
3. Normal Modes
4. Buckling
5. Direct or Modal Frequency Response
6. Direct or Modal Complex Eigenvalue
7. Direct or Modal Transient Response
8. Heat Transfer
9. Thermal-Structural Analysis

Due to the heterogeneous and layered nature of composites, multiple failure mechanisms affect the performance of composites during service.

Prazastinav Compositech Pvt Limited (PCPL) studies the damage build-up that can gradually lead to performance degradation and to ultimate failure.

• Progressive Failure Analysis: Predict progression of damage in the materials using any of the multiple failure criteria including Maximum Stress, Maximum Strain and so on….
• Delamination: Analyse weakening and failure of bond between the plies using Cohesive Zone Modelling technique.
• Crack Propagation: Simulate crack propagation using Virtual Crack Closure Technique (VCCT) to design products with better crack growth resistance.

The main task of the mechanical simulation is the optimization of components concerning weight and performance and safeguarding compliance with performance specifications. Using integrative simulation technology, we cover the simulation of hybrid materials consisting of composite sheets and short fiber reinforced plastics. The integrative approach takes the process and its influence on mechanical properties into account. Our mechanical simulation activities comprise:

• Stiffness calculations / structural analyses
• Strength analyses and failure prediction
• Crash behaviour
• NVH (Noise, Vibration, Harshness)

Prazastinav Compositech Pvt Limited (PCPL) engineers do both micro- and macro-scale analyses of composites to calculate their mechanical, thermal, and electrical properties for use in all sorts of downstream FEA analyses. By taking advantage of a complete suite of optimization capabilities, that include shape, sizing, and topology optimization, users can innovate faster.

We simulate the composite manufacturing process to ensure the following:

1. Analyze and optimize individual manufacturing operations
2. Link these operations by transferring material history from one operation to the next (change in fiber orientations, curing degree, temperature distribution)
3. Correct, optimize, or validate processes like draping, thermoforming, RTM, infusion, or curing, to minimize manufacturing defects, ensure reproducibility, and decrease development costs
4. Uniform and complete impregnation of the composite laminate
5. Absence of voids and dry patches – void-free composite laminate
6. Optimization of the impregnation time (in line with the resin gel times)
7. Predictable distortion and spring back post-curing
8. Minimize the draping-based orientation deviations during layup

Alongside high-performance hardware and software, this also requires highly-qualified and experienced experts who are in a position to create meaningful links between theory and practice. Providing CAE support for the development and analysis of new designs is one of our core services. We utilize state-of-the-art software to simulate the real-world behaviour of component designs. By utilizing the very latest simulation techniques, Prazastinav Compositech Pvt Limited (PCPL) can give you confidence in the quality and reliability of your designs, while, at the same time, significantly reducing the need for expensive and time-consuming trial-and-error work. Our Computer-Aided Engineering (CAE) Team uses state-of-the-art CAE tools for composite materials in both structural and Mouldability analysis. We offer product design, review, and consultation of the following

• Moulding analysis
• Structural analysis (FEA)
• Composites Parts and Products design assistance
• Mould design assistance
• Structural failure consultation
• Design assistance for metal-to-composite conversions
• Composite materials design assistance and education
• Composites composition assistance
• Quick mechanical structural design review
• Product testing recommendation

Our dedicated CAE Team uses different FEA software to review the structural requirements of a part or system in its application. Whether designing for one-time use or for an application in which creep or fatigue could cause failures, structural analysis is often a starting point in determining the strength of the material required and how the tooling needs to be built. One of the biggest challenges in structural analysis for complex Fibre reinforced materials is modelling the mechanical properties in a part that is Moulded with an anisotropic material. Software can be used to review Fibre orientation and determine what the mechanical properties will ultimately look like, and FEA can be used to determine the areas of highest stress. This is often an iterative process in which changes to design, material and tooling are all balanced to get an acceptable design.

 

We are specialized in formulating traditional as well as high end novel composites such as, glass-Fibres composites, carbon Fibres composites and tailor made composites. All the formulations are well tested in accordance with the local as well as International standards. Special grades developed for Electrical applications, automobiles and heavy engineering.

In a world where products are becoming ever more sophisticated, designers and manufacturers are always looking for materials that can deliver better strength-to-weight ratios and provide different qualities in the final product. This has led many manufacturers to look beyond traditional materials like metals and plastics, and to delve in more closely on composite materials. A composite material is made up of two or more different materials, with the final material displaying different properties to that of its constituents. With so many different materials being worked on and so many different possible combinations, naturally, composite materials engineering is a complex business and how you design and manufacture composites has a direct effect on the end product.

With years of experience, the team at Prazastinav Compositech Pvt Limited (PCPL) is uniquely qualified to help select the best composite materials that will meet all intended performance, quality, and cost standards. Our experienced polymer specialists work around the clock to formulate, test, and recommend different materials to match and/or surpass the intended requirements.

We use a variety of materials, some of which have even been developed, created, and patented exclusively by Prazastinav Compositech Pvt Limited (PCPL) for our customers. Whether you are looking for greater design flexibility, reduced operation costs, wear and tear resistance, or lower energy consumption, our team will go above and beyond to recommend an appropriate advanced composite materials solution for your individual application needs.

The Prazastinav Compositech Pvt Limited (PCPL) team excels at creating custom material formulations that combine materials in order to produce parts with physical properties that are not typically associated with “composites”. For example, some of our composite materials are structurally rigid, to replace steel, aluminium and other metals, yet retain elastomeric characteristics for impact & shock resistance, noise & vibration dampening, and shape “memory”.

Clearly, composite materials engineering can be a laborious process when an organization is striving to reach the right blend of materials with the right combination of properties. It could take months or even years of research to finally come up with the right mix of materials and the right construction methods. This leads to huge expenses and can make the developing of any new product an extremely expensive undertaking, even rendering it uneconomical or adding significant cost to the final product. Prazastinav Compositech Pvt Limited (PCPL) uses virtual prototyping techniques, to take the guesswork out of the process and arrive at better composites manufacturing solutions, faster. The goal of Virtual Prototyping is to obtain real-life results without physically testing real-life parts. In its unique approach to Virtual Prototyping, Prazastinav Compositech Pvt Limited (PCPL) integrates the properties inherited from materials and manufacturing processes into the virtual model to dramatically improve the accuracy and predictability of the virtual prototype. The result is a drastic drop in hardware prototyping.

Prazastinav Compositech Pvt Limited (PCPL) focuses specifically on the physics of materials, modelling how they will behave in the real world. Prazastinav Compositech Pvt Limited (PCPL) helps clients to model their manufacturing processes, creating the most efficient way to manufacture their products without investing in a costly plant or resorting to trial-and-error techniques.

Prazastinav Compositech Pvt Limited (PCPL) leads the way with a strategic focus on complex and cutting-edge applications of composite materials. With the passion for problem solving, Prazastinav Compositech Pvt Limited (PCPL) delves into offering the moulding and materials experience to customers wanting to apply the latest materials to a new or existing product.

Prazastinav Compositech Pvt Limited (PCPL) provides composite tooling for all composites processes: Injection, compression, open vacuum bag / lay-up tools, closed RTM with preforms, large thermoset and thermoplastic parts, carbon-fibre lay-up and large bonding assembly applications, advanced composites applications and many more. Tools are the starting point for any composite part manufacturing. The part is only as good as the tool it is made upon. Tools determine the part dimensions, surface finish, tolerances, shape as well as the part appearance, amongst other things.

Prazastinav Compositech Pvt Limited (PCPL) undertakes tooling design, development and manufacturing from the part 3D models with the partner organizations across the globe – paying utmost attention to the moulding strategy, release strategy as well as the manufacturing process compatibility. nDuring the developmental or optimisation stages, we ensure that the tooling’s activities are prioritised and since we specialize in both metallic as well as composite tooling, also ensure that our tools withstand repeated thermal and pressure curing cycles.

Typical types of tools we make are,

1. Metal Tools (Stainless Steel or Aluminium and alloys of the same)
2. Metal Tools (Invar with composite backing)
3. Composite Tools – Glass Fibre Based
4. Composite Tools – Carbon Fibre Based
5. Composite Tools – Self-Heated High Efficiency

 

We are also a pioneer in design and manufacturing of self-heated composite tooling

Prazastinav Compositech Pvt Limited (PCPL) produces composite applications for the Automotive, Aerospace, Marine & Recreation, Heavy Truck, Household, Agriculture, Heavy Engineering, Sports and Leisure, Electrical, Alternative Energy Industries, Defence and Aerospace sectors and many more applications and sectors

Mould production for composite part fabrication has played an increasing important role since 1986. Today, we specialize in designing and constructing precision, multi-piece Moulds for demanding applications---particularly highly detailed, complex parts through our partners from across the globe, many from the International Market. Having a team of professionally seasoned tool designers and toolmakers intimately familiar with the materials used in composite structures-such as carbon Fibre, Fibreglass, toughened epoxy, BMI, Polyimide and one-part epoxy systems makes us a resource of choice to the industry. Our knowledge of these materials and their unique processing parameters allows us to produce complex Moulds to exceptionally close tolerances for use in the RTM, Autoclave, Compression Mould , Injection Mould, Pultrusion, LRTM, RIM, VARTM and many other Processes.

Our ability to conceptualize, design and build the industry's most intricate tooling for composite part production has led to ongoing assignments with the world's principal manufactures of emerging sectors. Engineered Solution's tooling has been used to produce a variety of parts that are used on today's most highly engineered fields. These parts include from Electrical, Automotive to Defence and Aerospace sectors.

Elevating Performance and Style

Prazastinav Compositech Pvt Limited (PCPL) offers a full range of product development and prototyping services.

From rapid prototyping for form & fit using our state-of-the-art commercial 3D FDM printer, to the complete design and manufacturing of fully functional prototypes using our advanced composite processes.

Prazastinav Compositech Pvt Limited (PCPL) has the capability and experience to manufacture using most composite processes and all types of composite materials, including thermo-set, thermoplastic, autoclave & out-of-autoclave. We can help you develop the right manufacturing strategy as well as performing comparative processing studies to determine the best process for production of your product.

These services are complemented with an onsite, fully equipped test and inspection laboratory and certified personnel. We can validate that your product meets all of the required specifications.

1.  Expert knowledge for material selectio
2.  Expert knowledge for process selection
3.  CAD – quick turn-around tool and part design
4. Rapid prototyping (local RP suppliers)
5.  Composite wet layup / pre-preg
6.  Surfacing and paint

Prazastinav Compositech Pvt Limited (PCPL) can help by

• Building to your drawings, specifications, or ideas
• Determining the key risks and how to avoid them
• Building the first units and determining best processes, achievable tolerances, lowest weight, highest strength, and right stiffness
• Testing the first units to qualify to government or other specifications and demonstrating levels of performance

The Composite Prototyping Activities offers comprehensive testing services including getting the things executed to the best of the applications at our partnership organizations across the globe, of which many of the partnership organizations have fully equipped, in-house test facility, testing programs, and advanced compliance consulting services

Test Facility (with our partner facilities across the globe)

• Tensile Properties of Plastics
• Tensile Properties of Polymer Matrix Composite Materials
• Tensile Strength (Open Hole) of Polymer Matrix Composite Laminates Testing
• Flatwise Tensile Strength
• Compressive Properties of Rigid Plastics
• In-Plane Shear Strength of Reinforced Plastics
• Combined Loading Compression (CLC)
• Flexural Properties of Unreinforced and Reinforced Plastics
• Core Shear Properties of Sandwich Constructions
• Long Beam Flexure
• Compression After Impact
• Gel Time
• Tack
• Volatile Content
• Resin Flow
• Resin Content and Fibre Areal Weight
• Environmental Simulation Test Services, including; Shock, Vibration, Temperature, Temperature/Humidity, Salt Fog, Sand and Dust and many more

 

Prazastinav Compositech Pvt Limited (PCPL) also provides compliance consulting services. Thoroughly experienced experts are available to assist manufacturers in identifying the specific compliance testing requirements necessary to address their customer’s requirements.

Testing Programs

Consulting will be available to assist in the creation of testing programs that will allow for the broadest acceptance of products into multiple marketplaces. Testing related documentation services, including the generation of test plans and procedures, are also available.

 

The 'What' comes from our customers - we take care of the 'How'. When it comes to engineering, weight and functionality are key parameters that are just as important as costs and deadlines. The objective is to always provide the best turnkey solution for efficient right first time production. Customers can rely on Prazastinav Compositech Pvt Limited (PCPL) achieving this goal because we reduce development times by means of concurrent engineering and take customer orientation and proximity quite literally. Manufacturing Process Design is the most critical aspect towards ensuring consistency and repeatability in the parts manufactured. Ideally Product Design must consider Manufacturability aspects. We develop, optimize and transfer Composite Manufacturing Processes for our clients who, themselves, are leaders in the Advanced Composites sector.

Process development and optimization can either be initiated for a brand new project or for an established product (especially when the existing process is yielding unpredictable results).

Prazastinav Compositech Pvt Limited (PCPL) takes up Manufacturing Process Development right from the Mould Strategy onwards up to Final Quality Assurance Plans – integrating everything under its Process Framework.

Typically we end up with providing clients with specific measurable results like

• Reduction in Rejection
• Improve Consistency & Repeatability
• Assure Interchangeability
• Improve tolerances & meet stringent specifications
• Improve specifications of product (like void content, Fibre volume etc.
• Any other specific outcome desired by the client

Many times our final client for Process Development & Optimization are existing Composite Manufacturers themselves. We respect Customer Privacy & honor the Non-Disclosure Agreements with all our clients – ultimately, the relationships we have built are based on Trust.

Our experts have expertise in composite production and in efficient manufacturing. This combined expertise enables Prazastinav Compositech Pvt Limited (PCPL) to provide you the most appropriate system integration solutions for your production facilities. By applying the latest technologies, Prazastinav Compositech Pvt Limited (PCPL) creates solutions that give you more reliability, savings, safety, efficiency and therefore quick return on your investment. Based on our extensive experience and cooperation with many partners and suppliers, we can offer our customers the comprehensive solutions they can expect from us.

Whilst the manufacturing is being done, our design team put their mind to developing the other outputs for the client, they will produce detailed user manuals, maintenance manuals, specification sheets, general arrangement engineering drawings and other key documents that the client will need to accompany their product.

Prazastinav Compositech Pvt Limited (PCPL) Company can provide guidance and material data for customers doing their own CAE analysis. We have a proprietary company database and can do in-house testing and curve-fitting for both standard and custom materials. Your custom materials data will be processed with Prazastinav Compositech Pvt Limited (PCPL) ’s strict confidentiality procedures. If you do not find the Prazastinav Compositech Pvt Limited (PCPL) material you’re looking for in your injection Moulding software database, contact us! We have over 400 materials characterized for flow simulation and if your material is not already characterized, we can help you understand the details of how the material will behave and the level of testing required to accurately predict its behaviour during Moulding. Prazastinav Compositech Pvt Limited (PCPL) understands that the better the predictions are from the start, the better the overall project outcomes will be. With that being said, even if a reasonable material model doesn’t exist, we’ll test it for you!

Prazastinav Compositech Pvt Limited (PCPL)’s Data Analytics solution platform is a specialized set of solutions that combines state of the art Engineering Data Analytics and management approaches, intuitive visualization and efficient investigation methodologies to allow for a fast discovery of the unknown in large high-dimensional datasets.

Prazastinav Compositech Pvt Limited (PCPL) brings its long-standing innovative capability and its expertise in designing solutions tailored for professionals who need to solve difficult high-value problems.

Prazastinav Compositech Pvt Limited (PCPL) also helps its customers face the Big Data challenges induced by the ever-increasing size and complexity of simulation data. Considering the total cost of ownership of such simulation data, and all of the efforts needed to produce high-quality simulations, the Data Analytics solutions brought by Prazastinav Compositech Pvt Limited (PCPL) improve the ROI and leverage the benefits of critical knowledge captured by engineers.

Using our experience, we can select the right process depending on your product, the series and cost. Prazastinav Compositech Pvt Limited (PCPL) provides manufacturing engineering solutions that enable clients to perform virtual validation and optimization of manufacturing systems prior to the actual production, helping them reduce product realization cycle time and improve productivity.

Our Technical and Composites Expert Group have a unique combination of practical and theoretical experience from various industries and sectors to ensure that the composites manufacturing solutions are valuable from both a design and a manufacturing perspective. Together with the clients, Prazastinav Compositech Pvt Limited (PCPL) decides on the best combination of technology, machineries and equipment’s, system and process according to the need of the clients.

We support composite component manufacturers to optimize production performance for a wide range of composite products and processes

• Developing the most cost effective and efficient solutions that satisfy design to cost and design for manufacture
• Specifying material requirements, define suitable methods of manufacture and identify and implement tooling and equipment
• Developing processes to a production steady state standard that meets specification and design intent
• Support Production and Quality Assurance in resolving production problems and non-conformances
• Utilize Lean Principles to improve the product, process flow, build cycle and waste reduction
• Offer complete process coverage, from design and analysis to production
• Ensure manufacturability by integrating all requirements early in the design phase
• Perform structural and technical calculations
• Help you select the optimal core material and finishing
• Help you design the optimal kit
• Reduce the time and cost of production

At Prazastinav Compositech Pvt Limited (PCPL), we can determine the properties of a variety of polymers and polymer composite materials, providing you with reliable data. This data is supported by expert analysis and interpretation, allowing you to properly evaluate the performance of your materials.Our experts have the ability to produce accurate and fast composite product and materials test results for composites, and related materials. Prazastinav Compositech Pvt Limited (PCPL) defines the able tests for the composites parts and products for end use, avoiding future failures. Many products cannot be tested in a manner equivalent to their end use. Although it is possible to simulate operation by applying temperature and pressure changes, other conditions, such as bending and load combinations, cannot be reasonably simulated in a test situation. Through a combination of analytical modeling and non-destructive and destructive laboratory tests, Prazastinav Compositech Pvt Limited (PCPL) provides meaningful evaluations that are appropriate for the end use of the product and also defines the test methodologies to match to the exact product requirements.

Often, load conditions specified in composites testing standards do not relate to the actual end use of the product. Prazastinav Compositech Pvt Limited (PCPL) integrates a variety of analytical and testing techniques, such as tensile strength testing, ignition loss testing (burn test), and hydro and burst testing, combining the strengths of each to gain the highest confidence in the adequacy of the product for the intended service.

Prazastinav Compositech Pvt Limited (PCPL) support customers across the global aerospace, automotive, building, chemical, consumer, energy, manufacturing, medical, and materials industries with our world-leading facilities, experts, and solutions. Composite materials tested include thermoset and thermoplastic composites, laminates, Fibre reinforced composites, core materials, resins, films and adhesives.

• Reviews the product/equipment process and design requirements, including fabrication methods, corrosion requirements, and strength requirements.
• Determines expected laminate physical properties through laminate theory analysis after reviewing fabrication methods and raw materials.
• Determines the expected mode of failure for the equipment through engineering analysis, including first sign of failure and ultimate structural failure.
• Test the whole product or the critical parts of the equipment to determine capabilities. Test aids are employed as required to improve the analytical results, including strain gauging and Acoustic Emission testing.
• Along with the Test Laboratories who are an integral part of Prazastinav Compositech Pvt Limited (PCPL), we test the products for evaluating the exact product requirements, that would ensure matching with the concept and the theory.
• Report findings — including comparison of actual test results with theoretical analysis — for product analysis, evaluation, and confirmation.