Composite manufacturing feasibility with AFP

This service enables companies to assess and optimise the manufacturability of composite parts using AFP technologies, reducing development risks, minimising material waste, and improving production efficiency. It is particularly relevant for industries such as aerospace, automotive, and advanced manufacturing, where high-quality composite components and process reliability are critical.

The service evaluates whether the part design meets the technical constraints of AFP processes, including curvature limitations, fibre placement feasibility, and accessibility for robotic systems. Advanced path planning algorithms, supported by AI-based optimisation techniques, are used to generate and refine fibre placement strategies, improving accuracy and reducing defects.

The service includes:

• Geometry assessment to identify manufacturability constraints (e.g. curvature limits, complex geometries)
• Path planning calculation to define optimal fibre trajectories and minimise defects such as gaps or overlaps
• AFP manufacturing trial using robotic systems to validate the feasibility of the process under real conditions

The service follows a structured process:

• Review of the customer’s part design (e.g. CAD files, material specifications)
• Analysis of manufacturability constraints and process requirements
• Development and optimisation of path planning strategies
• Execution of AFP manufacturing trials
• Evaluation of results and identification of improvement opportunities

The expected outputs include:

• A technical report detailing manufacturability assessment, identified issues, and optimisation recommendations
• Validated path planning strategies ready for industrial implementation
• A manufactured prototype or demonstrator part, where applicable

Typical benefits include reduced development time, lower material waste, improved part quality, and increased confidence in scaling up AFP production. For example, aerospace manufacturers can validate complex composite structures before industrialisation, while equipment developers can optimise process parameters for new applications.

To carry out the service, customers are expected to provide part design data (e.g. CAD models), material specifications, and relevant process requirements. ITA provides AFP robotic systems, simulation tools, and expertise in composite manufacturing and AI-based optimisation.

This service is designed for:

• Composite part manufacturers seeking to industrialise AFP production processes
• Aerospace and automotive companies developing advanced lightweight structures
• Equipment and process developers aiming to validate and optimise AFP manufacturing strategies

To start a project, companies can contact ITA to define the part characteristics and manufacturing objectives. This initial step includes a feasibility assessment, followed by a tailored proposal, execution of trials, and delivery of results.