Cylindrical Multi-level Grid Structures Fabricated by Fiber Prepreg Tape Winding

SUN Shouzheng; GUO Zhenyu; RAN Xudong; LI Kuntai; HU Pan; HAN Zhenyu

doi:10.3969/j.issn.1674-6457.2026.02.005

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (2) : 48-59. DOI: 10.3969/j.issn.1674-6457.2026.02.005

Process Technology in the Ordnance Industry

Cylindrical Multi-level Grid Structures Fabricated by Fiber Prepreg Tape Winding

SUN Shouzheng¹, GUO Zhenyu¹, RAN Xudong^1,2, LI Kuntai¹, HU Pan³, HAN Zhenyu^1,*

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Abstract

The work aims to address the technical challenges of fiber accumulation and bridging at nodes in traditional filament winding for manufacturing composite multi-level grid structures, as well as the difficulty in achieving effective compaction of prepreg tows within deep groove molds. In this study, a dedicated prepreg tow winding head with a lightweight modular design and its precision control system were independently developed. The winding head integrated an adjustable tow guidance channel, a closed-loop tension control system for stable winding, an active thermal management unit combining “hot air heating” and “vortex tube cooling”, and a cutting and restart mechanism for complex paths. Based on the geometric characteristics of the Kagome multi-level grid, a “three-stage layered filling” winding strategy was planned, and corresponding equipment control code was generated via Python scripting. To ensure successful demolding of the complex component, a flexible silicone-plaster composite mold with a “negative draft angle” was designed and employed. Automated winding, forming, and curing experiments of composite cylindrical multi-level grid components were successfully conducted. The winding process was stable, fiber accumulation at the nodes was significantly reduced, the rib morphology was complete with tight interlayer bonding, and the cured, demolded component demonstrated good dimensional accuracy. Axial compression tests revealed a maximum ultimate load of 24 060.60 N, and the failure process exhibited a progressive damage mode characterized by interlayer separation and overall buckling, demonstrating the structure's high load-bearing capacity and damage tolerance. This research validates the feasibility of the developed winding head and staged winding process for fabricating complex multi-level grid structures, providing a new approach for the low-cost, high-quality automated manufacturing of high-performance composite grid structures.

Key words

composite grid structure / prepreg tape winding / winding head design / multi-level grid / forming process

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SUN Shouzheng, GUO Zhenyu, RAN Xudong, LI Kuntai, HU Pan, HAN Zhenyu. Cylindrical Multi-level Grid Structures Fabricated by Fiber Prepreg Tape Winding[J]. Journal of Netshape Forming Engineering. 2026, 18(2): 48-59 https://doi.org/10.3969/j.issn.1674-6457.2026.02.005

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