Simulation of Hybrid Radial Braiding Process for Composite Pressure Vessels 


Vol. 27,  No. 2, pp. 979-993, Feb.  2026
10.1007/s12221-025-01274-8


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  Abstract

Composite pressure vessels (CPVs) for hydrogen vehicles require irregular geometries with variable curvatures to maximize space utilization, presenting significant manufacturing challenges. Traditional filament winding excels in directional reinforcement but struggles with complex shapes, while conventional 3D braiding faces limitations in axial yarn tension and directional reinforcement at 0° and 90°. This study presents the first process simulator that integrates hybrid radial braiding and filament winding- a manufacturing approach that combines radial braiding's capability for three-dimensional complex preforms and filament winding's superior directional reinforcement. Unlike computationally intensive finite-element analysis-based simulations or single-process platforms, the developed kinematic simulator enables rapid prediction of critical manufacturing parameters, including yarn consumption, processing time, preform geometry, and cover factor through an intuitive graphical user interface. The simulator features real-time three-dimensional animation that visualizes the braiding process, facilitating understanding for users without specialized knowledge. Experimental validation across seven operating conditions demonstrated strong correlation between simulated and measured braid angles (r = 0.94, R2 = 0.89) with a mean absolute error of 6.40°, confirming the simulator's reliability for design-stage manufacturing predictions.

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  Cite this article

[IEEE Style]

Y. Lee and S. Kim, "Simulation of Hybrid Radial Braiding Process for Composite Pressure Vessels," Fibers and Polymers, vol. 27, no. 2, pp. 979-993, 2026. DOI: 10.1007/s12221-025-01274-8.

[ACM Style]

Yoojeong Lee and Sungmin Kim. 2026. Simulation of Hybrid Radial Braiding Process for Composite Pressure Vessels. Fibers and Polymers, 27, 2, (2026), 979-993. DOI: 10.1007/s12221-025-01274-8.

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