| Summary: | A finite element simulation was utilized in this work to analyze the thermoforming process of woven carbon fiber fabric/polyurethane thermoplastic composite sheets. In the simulation that may be classified as a discrete method, the woven carbon fiber fabric was treated as an undulated fill yarn crossed over an undulated warp yarn, and the resin was considered separately. Then, they were combined to represent the composite sheets. To verify this simulation, bias extension tests under three constant temperatures were executed. After that, the composite was thermoformed into a U-shaped structure and small luggage. From the bias extension tests, the finite element simulation and material properties of the fiber and resin were confirmed. From the comparison of the thermoformed products, the present simulation could provide the deformed profile and fiber-included angles and has good agreement with the experiment. The results also indicate that the stacking sequences of [(0°/90°)]<sub>4</sub> and [(+45°/−45°)]<sub>4</sub> have quite different product profiles and fiber-included angles.
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