Numerical simulation helps in the analysis of textile structures. It also supports the technical development of 3D preforms that are cut-free and woven to final contour, which is the prerequisite for a one-step manufacturing process (direct pre-forming). The simulation-based development process not only reduces trial-and-error, but also predicts the limits of current technology. The flexibility of the machine technology enables the production of multilayer and highly anisotropic preforms for high-performance FRP components. It has been shown that the production of certain 3D fabrics with fewer plies and a single weave works well. When producing 3D fabrics with more than 4 plies, the yarn-yarn friction on the warp yarn system increases strongly. At the same time, the shed cannot open completely. In order to keep the frictional forces low even with multilayer 3D fabrics, further investigations are required. For low-damage processing, a new technique with twin flat-steel healds is currently in the research phase.^6-7 This technique is based on the modification of the heald system, which makes it possible to position the warp threads on top of each other. The yarn-yarn friction during weaving is thus reduced and damage to the threads minimized.