Purpose -This study aims to introduce a predictive homogenization model incorporating electrical percolation considerations to forecast the electrical characteristics of unidirectional carbon-epoxy laminate composites.

Design/methodology/approach -We present a method for calculating the electrical conductivity tensor for various ply arrangement patterns to elucidate phenomena occurring around the interfaces between plies. These interface models are then integrated into a three-dimensional magneto-thermal model using the finite element method (FEM). A comparative study is conducted between different approaches, emphasizing the advantages of the new model through experimental measurements.

Findings -This research facilitates the innovative integration of electrical percolation considerations, resulting in substantial improvement in the prediction of electrical properties of composites. The validity of this improvement is established through comprehensive validation against existing approaches and experimentation.

Research limitations/implications -The study primarily focuses on unidirectional carbon-epoxy laminate composites. Further research is needed to extend the model's applicability to other composite materials and configurations.

Originality/value -The proposed model offers a significant improvement in predicting the electrical properties of composite materials by incorporating electrical percolation considerations at inter-ply interfaces, which have not been addressed in previous studies. This research provides valuable information to improve the accuracy of predictions of the electrical properties of composites and offers a methodology for accounting for these properties in 3D magneto-thermal simulations.