How does automated fiber placement (AFP) work for composite manufacturing?

AFP uses robotic systems to lay prepreg tape on complex contoured tools. Process: Multiple narrow tapes (0.125-0.5 inch) individually controlled; Compaction roller applies pressure and heat; Tape cut, added, or steered automatically; and Layer-by-layer buildup per ply schedule. Capabilities: Complex contours and compound curves, Steering for load-optimized fiber paths, Part-specific tape paths (no pattern cutting), and Large structures (fuselage, wing skins). Parameters: Layup speed (up to 1000 in/min), Compaction force, Heat input (IR, hot gas, laser), and Gap/overlap tolerances. Compared to hand layup: Higher repeatability and consistency, Reduced labor, Material waste reduction, and Process documentation. Limitations: Capital cost (~$2-5M per head), Path planning complexity, Minimum radius for steering, and Accessibility (head size). Applications: 787 fuselage sections, A350 wing skins. Quality: In-process monitoring, laser projection, and NDT of finished parts. AFP combined with automated inspection is standard for large composite structures.