Rising costs, shorter and shorter development times and the demand for all-encompassing digitalization bring together very complex issues, especially in the manufacturing of composites. Due to the large number of possible variations in the materials, the anisotropic properties and the abundance of process parameters, decisive factors come together. 

Every composite manufacturing process has certain challenges, whereby the pultrusion process with its continuous production sequence represents a special feature. In this context, the focus is on issues such as fibre guidance, impregnation and curing. With the help of an extensive process chain mapping on a digital level, initial approaches are given for a closed process simulation. Transient injection simulations can be used, for example, to calculate optimised and profile-adapted mould geometries and define process parameters such as haul-off speed or injection volume. In a research study, a simulation model for process optimisation of the pultrusion process was created using the finite volume method with an multi-phase model and a moving porous medium. These transient simulations were validated for the first time with a transparent and sensorised mould. A subsequent curing simulation can be used to simulate decisive findings on achievable process speeds, curing degrees and warpage behaviour. The results will be presented and validated based on a specific example. 

The potential savings from process simulation in terms of reducing time-consuming preliminary trails and expensive tools can be very high, especially in pultrusion. At present, the success in profile implementation is strongly based on the experience of the plant operators and is mostly implemented with classic resin systems in an open resin bath. However, with the knowledge gained and the possibilities of simulation, this can also be extended to fast-curing and higher-quality resin systems.