Automation of composite cryogenic tank design and optimization for space launcher application

This study discusses the development of a workflow to automate design and structural optimization of a composite cryogenic tank; a process that has traditionally been hindered by fragmented manual loops. The procedure encompasses different steps: creation of CAD model in CATIA V5 and implementation of stacking sequence with composite design add-on, mesh generation in HyperMesh and finite element method analysis in MSC Marc Mentat, with adequate boundary conditions.

This trial-and-error approach was inherently error-prone and has been replaced by modeFRONTIER, employed to orchestrate and optimize the workflow by interconnecting all the commercial tools involved in the process using already set up nodes. A key contribution of this work is the development of a dedicated connector - a custom integration designed to automate the complex parametrisation of the composite stacking sequence in CATIA V5. Built using Python and Windows COM technology, the connector facilitates the dynamic generation of ply groups, and the management of symmetrical and alternating sequences based on discrete input vectors.

The activity is carried out in collaboration with ESTECO developers with dedicated workshops and continuous support envisaged to learn to adopt the best approach in using modeFRONTIER suite. By successfully automating the entire process, this study establishes an optimization framework aimed at minimizing total mass while strictly adhering to structural constraints, such as the failure index and permissible stress levels. This integrated approach drastically enhances efficiency, reducing execution time by over 90% compared to traditional manual operations. The results validate the technical feasibility of high-fidelity optimisation for complex composite structures and provide a scalable foundation for future full-scale tank assemblies.