Fiber-reinforced Materials Research Articles

A continuum model for the mechanics of elastomeric sheets reinforced with extensible bidirectional fibers resistant to lateral pressure

We investigate the concurrent three-dimensional (in-plane and out-of-plane) deformations of fiber-reinforced composite (FRC) sheets undergoing lateral pressure. This involves the utilization of the Neo-Hookean strain energy model for the matrix material and computing the strain energy of bidirectional fibers by accounting for the stretching, bending, and twisting responses of the fibers. The kinematics of FRC are formulated within the framework of differential geometry on FRC surfaces, including the computations of the first and second gradient of deformation. By employing the variational principles, we derive the Euler equations describing the mechanics of the fiber–matrix composite system subjected to lateral pressure. The resulting three-dimensional continuum model theoretically predicts the deformation of the matrix material and it is found that the maximum deformation of matrix material occurs in the diagonal direction of the domain, yet, the center of the domain suffers weak in-plane deformation because of surface tension equilibrium. In addition, the stretching, bending, and twisting kinematics of fiber units are computed to investigate the effects of the individual fiber’s kinematics on the overall deformation of fiber meshwork. Lastly, it is found that the lateral pressure on the FRC surface induces fiber flexure in the vicinity of domain boundaries and fiber stretch inside the domain, corresponding to the intensified shrinking strain near the edges and stretching strain in the middle of the domain. The theoretical results provide phenomenologically meaningful insights into comprehending the damage patterns of the fiber-reinforced building material, the hemispherical dome shaping results of bamboo Poly (lactic) acid (PLA) composites and the out-of-plane deformation of woven fabric.

Research on computationally generative design of woven braced structure based on fiber composite material in architectural design industry

ABSTRACT With the intervention of computer algorithm-assisted design in the realm of contemporary architectural design, architectural spatial forms and corresponding design methods have improved significantly. However, the limitations of material strength and plasticity impose certain constraints on the architectural design of the new century. Based on this occurrence, this paper studies the development of a computational generative design system for woven braced structure composed of fiber-reinforced materials. Through experimental data of material performance, the research firstly argues feasibility of employing fiber composite materials to braced structure. The conclusion is that the structure designed and generated could produce a support of 1 ton per ㎡. Moreover, based on the ant colony algorithm and the algorithm principle of cellular automata on the Java platform, the study designs a generative system with iterative computing of force as the major axis to achieve the self-organization and adaptability of the braced structure. Above all, this paper proposes a design strategy engaging with computational generative design approach, as well as a design attempt for the material and form of architecture.

Using carbon fiber tape to tailor the coefficient of thermal expansion in 3D-Printed composite tooling

In this work, we investigated the effect of plain woven carbon fiber tape embedded in each layer of an additively manufactured part on the coefficient of thermal expansion (CTE) and compared it to conventionally printed parts. Current advancements in Additive Manufacturing enable cost-efficient 3D printing of composite tools. However, these tools do not yet offer a low CTE comparable to Invar, necessary for producing aerospace-quality composite parts. Using the novel Advanced Tape Layer Additive Manufacturing process, the tape is placed on top of the bead immediately after extruding the short fiber-reinforced material. The samples are compared to Material Extrusion specimens from a Large Format Additive Manufacturing System. A lower CTE was achieved within the printing plane. Micro-computed tomography images correlate the preferential orientation of short fibers with measured CTE values. The CTE modification can match the part CTE to the tool CTE and therefore optimize the quality of manufactured parts.

Innovative Skin Structures: Synthesis, Void Analysis, and Hysteresis Modeling of Zero Poisson’s Ratio Skin for Span Morphing Wing

This paper explores the use of carbon fiber-reinforced elastomeric skins for advancing flexible morphing wing technologies, highlighting exceptional 1D morphing capabilities. The study focuses on synthesizing a specially engineered elastomer-based skin with a zero Poisson’s ratio, achieved through precise formulation and fabrication onto unidirectional carbon fiber. Poisson’s ratio of the 1D skin is confirmed to be zero via image analysis. Micro-CT tomography evaluates carbon fiber quality and voids under varied prestretch conditions, revealing proportional increases in void sizes. X-ray tomography also provides insights into void distribution and morphology during pre- and post-cyclic stretching. The innovative approach enables seamless 1D morphing, achieving an impressive 200% stretch with a slight increase in actuation force and hysteresis loss percentage. Inspired by continuum mechanics, the proposed “Exp-ln-ln” framework accurately models the loading–unloading stretching of the skin. An extensive parametric investigation assesses key parameters, advancing fiber-reinforced elastomeric materials for aerospace morphing skins.

Biomimetic Mechanical Robust Cement-Resin Composites with Machine Learning-Assisted Gradient Hierarchical Structures.

Biological materials relying on hierarchically ordered architectures inspire the emergence of advanced composites with mutually exclusive mechanical properties, but the efficient topology optimization and large-scale manufacturing remain challenging. Herein, this work proposes a scalable bottom-up approach to fabricate a novel nacre-like cement-resin composite with gradient brick-and-mortar (BM) structure, and demonstrates a machine learning-assisted method to optimize the gradient structure. The fabricated gradient composite exhibits an extraordinary combination of high flexural strength, toughness, and impact resistance. Particularly, the toughness and impact resistance of such composite attractively surpass the cement counterparts by factors of approximately 700 and 600 times, and even outperform natural rocks, fiber-reinforced cement-based materials and even some alloys. The strengthening and toughening mechanisms are clarified as the regional-matrix densifying and crack-tip shielding effects caused by the gradient BM structure. The developed gradient composite not only endows a promising structural material for protective applications in harsh scenarios, but also paves a new way for biomimetic metamaterials designing.

Adapted Design Process for Continuous Fiber-Reinforced Additive Manufacturing-A Methodological Framework.

Continuous fiber-reinforced material extrusion is an emerging additive manufacturing process that builds components layer by layer by extruding a continuous fiber-reinforced thermoplastic strand. This novel manufacturing process combines the benefits of additive manufacturing with the mechanical properties and lightweight potential of composite materials, making it a promising approach for creating high-strength end products. The field of design for additive manufacturing has developed to provide suitable methods and tools for such emerging processes. However, continuous fiber-reinforced material extrusion, as a relatively new technology, has not been extensively explored in this context. Designing components for this process requires considering both restrictive and opportunistic aspects, such as extreme anisotropy and opportunities for functional integration. Existing process models and methods do not adequately address these specific needs. To bridge this gap, a tailored methodology for designing continuous fiber-reinforced material extrusion is proposed, building on established process models. This includes developing process-specific methods and integrating them into the process model, such as a process selection analysis to assess the suitability of the method and a decision model for selecting the process for highly stressed components. Additionally, a detailed design process tailored to continuous fiber-reinforced material extrusion is presented. The application of the developed process model is demonstrated through a case study.

Study on bearing capacity of corroded pipes before and after spraying rehabilitation

In recent years, there has been growing interest in trenchless technology, particularly in using centrifugal spraying technology to rehabilitate drainage pipelines. In this study, we evaluated the effectiveness of fiber-reinforced cement mortar spraying materials on pipes using the three-edge bearing test (TEBT) as per ASTM C497 standards. Six conditions of corroded and rehabilitated pipelines were tested: (1) corrosion depths, (2) corrosion widths, (3) corrosion positions, (4) pipe diameters, (5) loading rates, and (6) repair thicknesses. Through the TEBT, the structural bearing capacity and failure form of the pipe before and after repair were compared, and the bearing capacity difference of the pipe under different conditions was studied. Finally, a sensitivity analysis was conducted on the six variables. Among the many factors that affect the reliability of pipe structures, the influence degree of each factor is quite different. Through the parameter sensitivity analysis, the influence degree of each factor on the reliability of the structure can be clarified. The results show that the bearing capacity of the rehabilitated pipes is sufficient to meet the normal pipe bearing capacity requirements. The mortar lining and existing pipes can bear stress jointly, significantly increasing the maximum load of the rehabilitated pipes by up to 55.6 % and correspondingly reducing the circumferential strain. This indicates that the application of the mortar spraying lining layer effectively achieves the purpose of pipeline repair. This study provides valuable guidance for structural design optimization and safe operation.

Experimental study on fiber-reinforced cement tailings sand-based grouting material preparation and factors influencing the grouting effect

To address the problem of permeation of tailings pond initial dams rockfill dams, fiber-reinforced cement tailings sand-based grouting (FRCTG) material, which can be used for rockfill dam reinforcement, was prepared by selecting ordinary portland cement (OPC), iron tailings sand (ITS), basalt fiber (BF), fly ash (FA) and water as the raw materials. Orthogonal tests were used to investigate the effects of the water-binder ratio (w/b) and material mass fraction on the rheological and mechanical properties of FRCTG and determine the optimum mixing ratio. Comparative analyses were performed of the grouting effect of FRCTG and pure OPC grouting materials based on concrete self-compacting tests and COMSOL simulations. Combined X-ray diffraction (XRD) and scanning electron microscopy-energy spectroscopy (SEM-EDS) microstructural characterization were used to reveal the factors influencing FRCTG mechanical properties. The results showed that when the water-binder ratio (w/b) was 0.5, ITS substitution percentage for OPC was 10 %, BF dosage was 0.2 %, BF length was 6 mm, and FA substitution percentage for OPC was 8 %, FRCTG had better rheological properties and flexural strength than pure OPC grouting materials. In addition, FRCTG self-compacting concrete also had stronger compressive strength and splitting strength. FRCTG showed a better filling capacity and diffusion effect, which preliminarily verified the feasibility of rockfill dam grouting. ITS inhibited the hydration reaction of the cementitious material and prolonged the setting time of the slurry. The interlocking structure formed by FA and hydration products indirectly enhanced the flexural strength of the grouting material. BF not only provided FRCTG reinforcement but also acted as the hydration product skeleton. FRCTG demonstrated better economic and environmental performance than traditional cement material while effectively utilizing ITS and FA solid waste.

An experimental investigation on freeze-thaw resistance of fiber-reinforced red mud-slag based geopolymer

This study aims to investigate the influence of different fiber types, lengths, and contents on their performance in freeze-thaw environments. Indoor freeze-thaw tests were conducted to evaluate the flexural strength, compressive strength, and mass loss of fiber-reinforced geopolymer materials. Additionally, SEM and XRD analyses were performed to examine the internal structure of the geopolymer composites. The results demonstrated that the incorporation of different fibers significantly improved various properties, particularly the flexural strength of the specimens. With an increasing number of freeze-thaw cycles, surface cracks became more prominent in the geopolymer specimens, leading to a gradual decrease in frost resistance. However, the addition of an appropriate amount of fiber effectively enhanced frost resistance. Following freeze-thaw exposure, an increase in fiber content initially resulted in a decrease and subsequently an increase in relative flexural strength, compressive strength, and mass loss. Notably, studies revealed that polypropylene fibers with a length of 9 mm and a content of 0.9 % exhibited minimal mass and strength loss. SEM analysis indicated uniform distribution of fibers within the geopolymer matrix, contributing to improved flexural strength and enhanced frost resistance in fiber-reinforced structures. XRD results indicate that red mud-slag based geopolymers produce high-strength hydrated calcium (aluminosilicate) silicate and hematite phases, which enhances the mechanical properties and durability of the specimens. In conclusion, this study highlights that incorporating suitable fibers can enhance the durability and performance of red mud-slag based geopolymers under freeze-thaw conditions. The findings provide valuable insights for optimizing fiber type, length, and content to achieve superior mechanical properties and frost resistance in geopolymer composites.

Characterizing Cryptostegia grandiflora stem fiber for reinforcing lightweight polymer composites: A comprehensive study of its physical, chemical, and thermal properties

This study aimed to characterize Cryptostegia grandiflora stem fiber (CGSF) as a potential reinforcement material for lightweight polymer composites. Natural fiber-reinforced materials have gained attention as a promising alternative to synthetic fibers due to their comparable strength and modulus, and lack of harmful chemicals. The physical, chemical, and thermal properties of CGSF were investigated through fiber roughness, chemical measurement, physical measurement, Fourier transform infrared spectroscopy, XRD, water absorption, thermogravimetric analysis, and SEM conformation analysis. The results showed that CGSF has a high cellulose content (80.3 wt.%) and specific strength, making it suitable for use in polymer composites. Its flaky layered outer surface provides a high modulus, and its low microfibril angle observed through electron microscopy results in strong bonding qualities. The fiber also demonstrated improved heat stability up to 254–387 °C through thermogravimetric analysis, meeting the requirements for polymerization. These findings demonstrate the potential of CGSF as a natural reinforcement material for lightweight polymer composites.

In situ interlaminar shear behavior of carbon fibers reinforced polymer composites exposed to severe thermal aggressions: PPS versus epoxy laminates

This study investigates the influence of a combined thermal heat flux and a flexural loading on the interlaminar shear behavior of quasi-isotropic carbon fibers reinforced PPS and Epoxy laminates. Regardless the intensity of the heat flux (ranging from 20 to 50 kW/m2), the maximum surface temperature is higher than the onset of thermal decomposition [Formula: see text] in C/Epoxy laminates ([Formula: see text]) whereas the thermal decomposition is reached only for 40-50 kW/m2 heat fluxes in C/PPS laminates ([Formula: see text]). A mechanical bench was specifically designed to study the interlaminar shear behavior of polymer-based laminates during the thermal aggression (imposed by a cone calorimeter). In C/PPS laminates, with respect to the reference values (as received state), the flexural modulus and the apparent ILSS (under 50 kW/m2) decreases by about 80%. In C/Epoxy laminates, with respect to the reference values (as received or virgin state), the flexural modulus and the apparent ILSS (under 50 kW/m2) decreases by about 20% and 50%, respectively. In carbon fiber-reinforced polymer materials, the matrix state is crucial for preserving the cohesion of the fibers network and the bonding of the plies together, a role that seems compromised in C/Epoxy and C/PPS laminates under high heat flux conditions, once the pyrolysis of the matrix has severely degraded the interlaminar properties of the material.

Suitability of using areca nut fiber as reinforcing material in compressed stabilized earth blocks (CSEB) for low-cost housing

An economical and cost-effective replacement for conventional building materials is Compressed Stabilized Earth Block (CSEB). However, they are vulnerable to erosion and cracking, particularly in humid settings. The use of natural fibers as reinforcement is found effective in overcoming this problem. Areca nut fiber which is a complete waste material in countries like Bangladesh and India is also a sturdy, adaptable, and water-resistant natural fiber that makes it the perfect choice as fiber reinforcement material for CSEBs. In this article, the strength performance analysis of areca nut fiber as a reinforcement material for CSEBs is investigated, where 0%, 0.85%, 2%, 5%, and 8% of areca nut fiber is mixed with soil that is stabilized with 10% cement. CSEB specimens of 4″ × 4″ × 4″ size have been made and tested for compressive strength, tensile strength, bulk density, and water absorption. It is observed that there is an 83.76% increase in compressive strength and an 8.89% increase in splitting tensile strength for 0.85% of areca nut fiber content specimen cured for 90 days. The water absorption was found a minimum of 9.07% for 0.85% areca nut fiber content and the minimum density of the block was observed at 1810 kg/m3 for the optimum percentage of 0.85% mix. The study indicates that using 0.85% of areca nut fiber content in stabilized CSEB shows a significant improvement in the strength characteristics of compressed stabilized earth blocks.Graphical

Optimization mechanism of metakaolin on micro-mechanical properties and pore characteristics of steel fiber-cement matrix interface

The study investigated the influence of aeolian sand and metakaolin (MK) on the micro-mechanical properties and pore structure characteristics of the interfacial transition zone (ITZ) between steel fibers and matrix in steel fiber-reinforced cement-based materials by nanoindentation, scanning electron microscopy (SEM) imaging, and energy-dispersive spectroscopy (EDS) analysis. The results demonstrated that including MK and aeolian sand led to a denser and uniform micro-structure in the ITZ, along with reducing the porosity and refining the pore size within there. Furthermore, MK could enhance the micromechanical properties of the C-(A)-S-H) gel by increasing the Al/Si ratio. Finally, the Copula function further confirmed the correlation between porosity (pore size >0.2 μm) and micro-mechanical properties in the ITZ. This study provides a theoretical basis for the engineering application of aeolian sand and metakaolin, and proves the feasibility of porosity to characterize the microscopic mechanical properties of the interfacial transition zone of cement-based materials. Thus, it has specific engineering value and academic significance.

Anisotropic Hyperelastic Strain Energy Function for Carbon Fiber Woven Fabrics.

The present paper introduces an innovative strain energy function (SEF) for incompressible anisotropic fiber-reinforced materials. This SEF is specifically designed to understand the mechanical behavior of carbon fiber-woven fabric. The considered model combines polyconvex invariants forming an integrity basisin polynomial form, which is inspired by the application of Noether's theorem. A single solution can be obtained during the identification because of the relationship between the SEF we have constructed and the material parameters, which are linearly dependent. The six material parameters were precisely determined through a comparison between the closed-form solutions from our model and the corresponding tensile experimental data with different stretching ratios, with determination coefficients consistently reaching a remarkable value of 0.99. When considering only uniaxial tensile tests, our model can be simplified from a quadratic polynomial to a linear polynomial, thereby reducing the number of material parameters required from six to four, while the fidelity of the model's predictive accuracy remains unaltered. The comparison between the results of numerical calculations and experiments proves the efficiency and accuracy of the method.

Effect of fiber-reinforced direct restorative materials on the fracture resistance of endodontically treated mandibular molars restored with a conservative endodontic cavity design

ObjectiveThis study aimed to evaluate the fracture strength of teeth restored using fiber-reinforced direct restorative materials after endodontic treatment with a conservative mesio-occlusal access cavity design.Materials and methodsA total of 100 extracted intact mandibular first molars were selected and distributed into a positive control group where teeth left intact and the following four test groups comprised of teeth with conservative mesio-occlusal access cavities that had undergone root canal treatment (n = 20/group): access cavity without restoration (negative control), bulk-fill resin composite with horizontal glass fiber post reinforcement, fiber-reinforced composite with bulk-fill resin and bulk-fill resin composite. Following thermocycling (10,000 cycles), fracture resistance was measured using a universal testing machine. Statistical analyses (one-way analysis of variance and the Tamhane test) were performed, and statistical significance was set at p < 0.05.ResultsGroups with minimally invasive access cavities had lower fracture strength than intact teeth, regardless of the restoration material (p < 0.05). Fiber-reinforced composite groups demonstrated higher fracture strength than bulk-fill resin composite alone (p < 0.05). Fracture types varied among groups, with restorable fractures predominant in the fiber-reinforced composite groups.ConclusionThis study suggests that using fiber-reinforced composite materials, especially in combination with bulk-fill resin composites, can effectively enhance the fracture strength of endodontically treated teeth with conservative access cavities. However, using only bulk-fill resin composite is not recommended based on the fracture strength results.Clinical significanceWhen teeth that undergo endodontic treatment are restored using a conservative access cavity design and fiber-reinforced composite materials, especially in combination with bulk-fill resin composites, the fracture strength of the teeth can be effectively increased.

Biomimetic laminated fiber-reinforced composites with a co-enhancement of strength and toughness

The co-enhancement of strength and toughness (damage-tolerant) is an urgent demand for most fiber-reinforced materials. Unfortunately, these properties are generally mutually exclusive. Hence, it is highly desirable yet challenging to develop new fiber-reinforced structural materials with high strength and toughness. Herein, inspired by the dual-stage rigid-flexible coupling structures (RFCSs) of abalone shell, a biomimetic carbon fiber reinforced composite (BCFRC) was prepared using a method combing droplet-based additive manufacturing and infrared heating-assisted thermoforming. Remarkably, the BCFRC features a unique coordination of high strength (1204 MPa), high toughness (6.29 MJ·m−3), and high stiffness (104 GPa) in tensile tests, benefiting from the co-effect of energy dissipation of brick-and-mortar architected laminates (first-stage RFCS) and the resistance to stress concentration of resin matrix embedded with silanized particles (second-stage RFCS). This work highlights the potential of harnessing the rich designability of fiber prepreg and resin matrix to build high-performance fiber-reinforced materials with bioinspired complex architectures.

Analysis of Mechanical Properties of Fiber-Reinforced Soil Cement Based on Kaolin.

Adding fibers into cement to form fiber-reinforced soil cement material can effectively enhance its physical and mechanical properties. In order to investigate the effect of fiber type and dosage on the strength of fiber-reinforced soil cement, polypropylene fibers (PPFs), polyvinyl alcohol fibers (PVAFs), and glass fibers (GFs) were blended according to the mass fraction of the mixture of cement and dry soil (0.5%, 1%, 1.5%, and 2%). Unconfined compressive strength tests, split tensile strength tests, scanning electron microscopy (SEM) tests, and mercury intrusion porosimetry (MIP) pore structure analysis tests were conducted. The results indicated that the unconfined compressive strength of the three types of fiber-reinforced soil cement peaked at a fiber dosage of 0.5%, registering 26.72 MPa, 27.49 MPa, and 27.67 MPa, respectively. The split tensile strength of all three fiber-reinforced soil cement variants reached their maximum at a 1.5% fiber dosage, recording 2.29 MPa, 2.34 MPa, and 2.27 MPa, respectively. The predominant pore sizes in all three fiber-reinforced soil cement specimens ranged from 10 nm to 100 nm. Furthermore, analysis from the perspective of energy evolution revealed that a moderate fiber dosage can minimize energy loss. This paper demonstrates that the unconfined compressive strength test, split tensile strength test, scanning electron microscopy (SEM), and mercury intrusion porosimetry (MIP) pore structure analysis offer theoretical underpinnings for the utilization of fiber-reinforced soil cement in helical pile core stiffening and broader engineering applications.

4D printing of fiber-reinforced auxetic structures: the building blocks: A review

Abstract Four-dimensional (4D) printing has recently received much attention in the field of smart materials. It concerns using additive manufacturing to obtain geometries that can change shape under the effect of different stimuli. Such a technique enables the fabrication of 3D printed parts with the additional functionality of scalable, programmable, and controllable part shapes over time. &amp;#xD;This review provides a comprehensive examination of advances in the field of 4D printing, emphasizing the integration of fiber reinforcement and auxetic structures as crucial building blocks. &amp;#xD;The incorporation of fibers enhances structural integrity, while auxetic design principles contribute unique mechanical properties, such as negative Poisson's ratio and great potential for energy absorption due to their specific deformation mechanisms. Therefore, they present potential applications in aerospace, drones, and robotics.&amp;#xD;The objective of this review article is first to describe the distinctive properties of shape memory polymers (SMPs), auxetic structures, and composite (fiber-reinforced) materials. A review of applications that use combinations of such materials is also presented when appropriate. The goal is to get a grip on the delicate balance between the different properties achievable in each case. The paper concludes by describing recent advances in 4D printing of fiber-reinforced auxetic structures.&amp;#xD;

Impact of aluminate cements on the durability and mechanical performance of strain-hardening cementitious composites

Strain-hardening cementitious composites (SHCCs) are durable, ductile, fiber-reinforced cement-based materials. While fly ash (FA) is often used to partially replace Portland cement in SHCCs to enhance material performance, it can lead to long setting times and slow strength development. To address these limitations, this study investigates the use of aluminate cement as partial replacements for Portland cement in FA-based SHCCs. Furthermore, the study aims to fill a significant knowledge gap by thoroughly examining the influence of aluminate cement on the workability, durability, and strain-hardening behavior of SHCCs. Aluminate cements encompass both calcium sulfoaluminate (CSA) cement and calcium aluminate cement (CAC), distinguished by their composition rich in calcium aluminate phases. This study investigated the use of CSA and CAC cements as partial replacements for Portland cement in SHCCs. Both fresh and hardened properties of the CSA- and CAC-SHCCs were examined, while their microstructures and chemical phases were investigated using SEM and XRD analyses. Results showed that CSA and CAC cements reduced fluidity, setting time, and drying shrinkage but increased porosity and early strength development for SHCCs. CSA-SHCCs showed enhanced impermeability due to the refinement of interior pore space through the hydration products. While all modified SHCCs retained tensile strain hardening behavior, the tensile performance degraded due to the hydration effects of ye'elimite and calcium aluminates. The reduced tensile strain capacity was elucidated using the theory of steady-state crack opening.

Design Principles and Restrictions for Continuous Fiber-Reinforced Additive Manufacturing

Abstract In the development of innovative and high-performance products, design expertise is a critical factor. Nevertheless, novel manufacturing processes often frequently lack an accessible comprehensive knowledge base for product developers. To tackle this deficiency in the context of emerging additive manufacturing processes, substantial design knowledge has already been established. However, novel additive manufacturing processes like continuous fiber-reinforced material extrusion have often been disregarded, complicating the process's wider dissemination. The importance of design knowledge availability is paramount, as well as the need for user-friendly design knowledge preparation, standardized structure, and methodological support for accessing the accumulated knowledge with precision. In this paper, we present an approach that provides formalized opportunistic and restrictive design knowledge, ensuring both the comprehensive exploitation of process-specific potentials and the consideration of restrictive limitations in the construction of components. Opportunistic knowledge, presented as principle cards, is systematically derived, prepared, and made accessible. Moreover, an access system is developed to ensure the comprehensive utilization of process-specific potentials throughout the development process. Furthermore, we propose linking these principles through a synergy and conflict matrix, aiming to consider synergistic principles and identify potential conflicts at an early stage. Additionally, an approach to provide restrictive design knowledge in the form of a design rule catalog is proposed. The application of the knowledge system is demonstrated exemplarily using a weight-optimized component.