This paper concerns engineered composites integrating metallic particles to enhance thermal and electrical properties. However, these properties are strongly dependent on the forming process itself that determines the particle distribution and orientation. At the same time, the resulting enhanced thermal properties affect the reinforced resin viscosity whose flow is involved in the intimate contact evolution. Thus, a subtle and intricate coupling appears, and the process cannot be defined by ignoring it. In this paper, we analyze the effects of particle concentration and orientation on the process and processability. For this purpose, three main models are combined: (i) a multi-scale surface representation and its evolution, by using an appropriate numerical model; (ii) flow-induced orientation, and (iii) the impact of the orientation state on the homogenized thermal conductivity.
Keywords: PGD; consolidation; microwires; prepreg; reinforced resins; squeeze flow; wavelet surface representation.