Numerical Modelling and Validation of Non-Woven Materials for Industrial Applications

This thesis investigates the mechanical virtual modelling of highly porous non-woven materials with anisotropic mechanical behaviour, developed in collaboration with the R&D centre of Procter & Gamble in Schwalbach am Taunus, Germany. Within the market, non-woven materials are widely used in P&G products, where reliable prediction of mechanical performance is essential to support product design, guide material development, and ensure functionality and quality across a broad range of application scenarios. Effective virtual modelling helps reduce time to market, minimize the need for extensive physical testing, and lower prototyping costs. To support the modelling work, a literature review was carried out to explore the current state of research in mechanical modelling of non-wovens, with particular attention to their behaviour under compressive and bending loads. The review also included an analysis of experimental characterization techniques used at various length scales, which are important to capture the complex deformation mechanisms of these fibrous structures and inform reliable simulation strategies. A finite element model was developed in LS-DYNA for the simulation of the mechanical response of the material subjected to z-axis compression and three-point bending tests, applied both to single-material and multilayered configurations. The objective was to validate the model for the multilayered configuration by comparison with experimental results. The model is based on a pre-existing internal approach, which was modified and integrated to enable verification of reproducibility and analysis of methodological robustness. The validation process was supported by a laboratory prototyping phase. The model demonstrates predictive capability for single-layer configurations and highlights certain limitations for multilayered systems. This work emphasizes the balance between industrial relevance and scientific rigor and lays the groundwork for future advancements in virtual testing and material optimization within the consumer goods industry.