Carbon Fiber Design Optimization with Finite Element Analysis (FEA)
Simulate, refine, and manufacture high-performance composite structures — faster and lighter.
At Element 6 Composites, we use FEA to drive intelligent composite design. Our simulation-backed workflow helps reduce development time, minimize weight, and create structurally sound components — long before the first prototype is built.
How Finite Element Analysis Works
FEA breaks down complex parts into small elements to simulate how they respond to real-world loads. These elements can be:
- 1D: Rods and beams for frames and trusses
- 2D: Shells and plates for laminate skins
- 3D: Solids for thick or contoured parts
Material behavior, fiber direction, support conditions, and interface constraints are all incorporated into the model to accurately predict structural performance.
Structural Simulation for Fiber-Reinforced Composites
We specialize in the simulation of carbon fiber and composite laminates under structural loading. Our composite-specific FEA capabilities include:
- Stress and strain mapping across plies
- Panel deflection and stiffness predictions
- Inter-laminar shear near joints and fasteners
- Safety margin checks against material limits
- Optimization of layup, thickness, and core choice
These insights enable stronger, lighter, and more cost-effective part designs.
We Work Side by Side With You
We don’t just deliver results — we partner with you to evolve your design. Our simulation engineers work directly with your team to:
- Refine layups and fiber orientations
- Evaluate weight-saving options
- Compare cost-performance trade-offs
- Maintain design intent from concept through manufacturing
Through simulation and shared iteration, we help transform your idea into a refined, ready-to-build solution.
FEA-Led Design Iteration
We use simulation to rapidly explore geometry changes, material tweaks, and structural reinforcements. This lets us:
- Reduce deflection under load
- Improve stiffness with minimal thickness
- Eliminate weak points before they cause failure
- Reduce prototype cycles and development time
- Optimization of layup, thickness, and core choice
Small changes. Big results.
Real Results. Ready for Manufacturing.
Our models are built on NEi Nastran, a proven solver with aerospace heritage. We deliver actionable outputs you can build from:
- Clear laminate schedules and ply specs
- Core and bonding recommendations
- Guidance for tooling and layup
- Engineering-level confidence in performance
We bridge the gap between digital simulation and physical reality.
From Analysis to Fabrication
Our designs are meant to be built — not just analyzed. We work within your constraints to ensure each simulated solution is practical for:
- Hand layup or prepreg manufacturing
- Sandwich panels with core material options
- Co-curing, bonding, or fastening assemblies
- Realistic tolerance and tooling considerations
We don't stop at a good design — we deliver a manufacturable one.
Why Choose Element 6 for FEA?
- Lighter, stronger designs tailored to your loads
- Faster development with fewer physical trials
- Simulation-informed decisions from the start
- Collaboration from concept to tooling
- Engineering credibility you can pass to your customer
Ready to Optimize Your Composite Design?
Upload your drawing, sketch, or requirements and our simulation team will provide a no-obligation design review. Whether you're starting from scratch or upgrading an existing part, we’re ready to help.
