This presentation outlines a strategy for designing composite structures accounting for the presence of defects that are inevitable in a practical manufacturing process. The essential ingredients of the strategy are incorporation of defects in physical models for assessment of composite performance and connecting the performance metrics to defect severity measures. A cost/performance trade-off then leads to cost-effective design. To illustrate the strategy, two examples of failure in composites under transverse tension and under axial compression are taken. Stochastic simulations of representative volumes are conducted to develop defect severity measures and to assess failure. Experimental data are taken to validate the predictions of the physical models and parametric studies are performed to illustrate trends in effects of manufacturing defects on design thresholds.
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