Porosity Matters: Multiscale Simulation of Composite Panel Performance in Aerospace Structures

Porosity in carbon fibre reinforced polymers (CFRP) remains a critical concern for aerospace engineers, as even minor voids introduced during manufacturing can undermine the reliability of structural components. This work explores the influence of interply porosity on composite panel behaviour, employing a multiscale simulation approach that bridges material characterisation and full-scale structural analysis. The study begins with virtual coupon testing using Digimat-VA and Digimat-MF, enabling the prediction of material allowables and the assessment of defect variability. Homogenised material properties derived from these simulations are then applied to detailed panel models constructed in MSC Apex, ensuring accurate representation of layup and orthotropic behaviour. The workflow can support a range of structural load cases, allowing for the evaluation of stiffness, buckling, or other relevant scenarios as dictated by aerospace certification requirements. Nonlinear finite element analysis is performed in SOL400, comparing pristine panels with those containing a defined level of porosity. The results highlight a marked reduction in stiffness and strength for porosity-affected panels, underscoring the importance of defect control in both design and manufacturing. The approach demonstrates how advanced digital tools can accelerate the assessment of damage tolerance, reduce reliance on physical testing, and support the certification process. By integrating virtual materials laboratory capabilities with robust structural simulation, this methodology offers a practical framework for understanding and mitigating the risks associated with manufacturing defects in aerospace composites. The findings are directly relevant to engineers seeking to optimise composite structures for safety, performance, and regulatory compliance.