Continuous Improvement in Composite Manufacturing: A Review of Automated Fiber Placement Process Evolution and Future Research Prospects

Continuous improvement and refinement on the application level of composites is essential for advancing the capabilities and reliability of various industries. Automated Fibre Placement (AFP) sets new standards for precision in aircraft manufacturing. Current research initiatives encompass diverse aspects, such as advanced materials, intelligent robotic systems, and adaptive control strategies, all contributing to the refinement of fibre placement applications, for industries reliant on lightweight, high-performance composite structures. The development of AFP technology can be traced through several key phases, beginning with its early experimental stages, progressing through periods of rapid industrial adoption and integration, to its current status as a critical technology in modern manufacturing. These phases mirror broader trends in the use of carbon fibre-reinforced polymer matrix composites (CFRPs), increased adoption into non-aerospace sectors, despite global challenges, such as the 2021 downturn in aerospace-related CFRP consumption. AFP continues to evolve, with growing demand driven by the need for more efficient and sustainable manufacturing processes. This review provides a comprehensive overview of the AFP process, covering material selection, fibre placement techniques, manufacturing, and quality inspection. It highlights key challenges in process optimization and explores future directions, including advancements in adaptive control, real-time monitoring, and machine learning for a more efficient, closed-loop AFP process.