Thermal and Pressure Digital Twins from Online Process Control for Data-Based Optimization of Laser-Assisted In Situ Consolidation of High-Performance Composite Parts

Abstract
Automated Fiber Placement (AFP) enables precise deposition of thermoplastic tapes on
complex geometries, however variations in temperature, compaction pressure, deposition
speed, and tooling conditions can affect the final laminate quality. This study presents an
integrated real-time monitoring system and a systematic methodology for process/product
data analysis linking process parameters to mechanical and microstructural performance.
Mechanical testing evaluation by interlaminar shear strength (ILSS), thermal analysis, and
microscopy studies identified both the consolidation and mold temperatures as the critical
parameters for optimized mechanical properties. Results showed ILSS above 45 MPa,
crystallinity up to 37.9%, and minimal porosity (~1%). Digital tools developed provided full
traceability, early instability detection, and continuous optimization, enhancing reliability
and repeatability in high-performance thermoplastic composite manufacturing, which
paves the way towards zero-defect manufacturing.