New Paper on Automated Fibre Placement (AFP):
Precision Meets Challenges
Automated Fibre Placement (AFP) is transforming the way advanced composite materials are manufactured, especially for the aerospace sector where strength, weight, and reliability are crucial. A new paper produced by CAELESTIS consortium partners AIMEN, “Influence of Automated Fibre Placement (AFP) Parameters over Laminate Quality”, explores how the specific settings and parameters of AFP impact the final quality of such composite laminates. This research is not just an academic exercise; it is a key part of the ambitious CAELESTIS project, which aims to revolutionize aircraft manufacturing in Europe.
AFP is a sophisticated manufacturing process where robots lay down strips of carbon fibre onto a mould, building up complex shapes layer by layer. This technology allows for the creation of lighter, stronger aircraft parts, which is essential for reducing fuel consumption and emissions. However, the process is not without its challenges. The paper highlights how even small errors in fibre placement, such as gaps, overlaps, or misalignments, can lead to defects inside the material. These defects, like voids or areas with uneven resin flow, can weaken the final product and compromise safety.
The authors review how key AFP parameters, including the speed at which fibres are laid down, the pressure applied during placement, and the temperature of the process, affect the likelihood of these defects. For example, moving too quickly can cause fibres to shift or buckle, while too much pressure can distort the fibres themselves. The interplay between these variables is complex, and finding the right balance is critical for producing high-quality laminates.
What makes this research especially significant is its integration into the CAELESTIS project, a major European Union-funded initiative. CAELESTIS brings together leading aerospace companies, universities, and digital technology firms to create a new digital ecosystem for aircraft design and manufacturing. The project’s goal is to enable the next generation of aircraft, lighter, more efficient, and more environmentally friendly, by harnessing cutting-edge digital tools and artificial intelligence.
Within CAELESTIS, the findings from the AFP paper are being put into practice through a novel approach that combines real-time monitoring, predictive modelling, and adaptive manufacturing. The process begins with sensors embedded in the AFP equipment that continuously scan each layer of fibre as it is placed. This data is fed into advanced machine learning models, specifically, a type of artificial intelligence called a Variational Autoencoder. Trained on tens of thousands of simulated AFP scenarios, this model can predict how even minor placement errors will affect the flow of resin and the formation of voids during the curing process.
If the system detects a potential problem, it can automatically adjust the placement of subsequent fibre layers to compensate, effectively “healing” the laminate as it is built. For instance, if a gap is detected in one layer, the machine might add extra fibres nearby in the next layer, or subtly change the angle of placement to ensure even resin distribution. In laboratory tests, this adaptive approach has been shown to reduce voids by more than 50% and produce laminates with much more consistent properties, an important step forward for safety and performance.
The implications of this work extend far beyond the laboratory. CAELESTIS is designed to support Europe’s push for climate-neutral aviation by 2050. Traditional aircraft designs are reaching their limits in terms of efficiency, and new, more radical designs, such as blended-wing bodies, require manufacturing techniques that can guarantee the integrity of complex composite parts. By integrating the AFP methodology described in the paper into a broader digital workflow, CAELESTIS is helping to make these new designs feasible. The project’s digital ecosystem links design, simulation, manufacturing, and quality control in real time, creating a “digital twin” of each part that can be used to speed up certification and reduce development costs.
The collaborative nature of CAELESTIS is also worth noting. Partners like GKN Aerospace, TU Delft, and ESI Group are working together to validate these new manufacturing methods on real aircraft components, using both physical testing and high-fidelity simulations. By 2025, the project aims to have this ecosystem in place across the European aerospace sector, potentially cutting development timelines for new aircraft by a third or more.
The research presented in this paper represents a cornerstone of the CAELESTIS project’s vision for the future of aviation. By understanding and controlling the variables that affect laminate quality, and by embedding this knowledge into a connected, intelligent manufacturing system, CAELESTIS is paving the way for safer, greener, and more innovative aircraft.
The results are not just technical improvements, they represent a major step toward a more sustainable and competitive European aerospace industry!
