Multi-Fidelity Reliability-Based Design Optimization of Advanced Composite Structures
Dario ZAMANI, Alfonso PAGANI, Marco PETROLO, Erasmo CARRERA
Abstract. This paper presents a Multi-Fidelity Reliability-Based Design Optimization (MF-RBDO) strategy for Automated Fibre Placement (AFP) tow-steered composite structures. The framework combines manufacturing-aware fibre-path design, uncertainty propagation and multi-fidelity structural theories based on the Carrera Unified Formulation (CUF). The composite optimization framework is posed as a mixed-integer problem, where the number of plies is discrete and the tow-steering parameters are continuous. Deterministic AFP constraints on curvature, gaps and overlaps are enforced before the structural analysis, while stochastic variability in material properties, load, thickness and fibre angles is propagated through a multi-fidelity Gaussian Process Regression (GPR). Low-fidelity Equivalent-Single-Layer models provide inexpensive exploration, whereas high-fidelity Layerwise descriptions enrich the surrogate in regions where through-thickness stresses and failure indices are critical. A benchmark tow-steered plate shows that the reliability-based solutions require only a modest mass increase, but reduce the predicted failure indices and make the design less sensitive to manufacturing-signature variability.
Keywords
Tow-Steered Composites, Reliability-Based Design Optimization, Multi-Fidelity Modeling, Carrera Unified Formulation, Gaussian Process Regression
Published online 11/8/2026, 6 pages
Copyright © 2026 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Dario ZAMANI, Alfonso PAGANI, Marco PETROLO, Erasmo CARRERA, Multi-Fidelity Reliability-Based Design Optimization of Advanced Composite Structures, Materials Research Proceedings, Vol. 73, pp 177-182, 2026
DOI: https://doi.org/10.21741/9781644904459-35
The article was published as article 35 of the book Mechanics of Advanced Materials and Structures
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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