addcomposites.com/... In this comprehensive blog, we delve into the automated fiber placement process, a crucial technique for manufacturing high-performance composite components. We discuss the importance of optimizing process parameters to ensure the highest quality of the final product and examine the factors that affect its quality, including raw material characteristics, mandrel factors, compaction roller dimensions, and heat source variables. We then explore how Design of Experiments (DOE) can be used to analyze and optimize these parameters, leading to improved voids, crystallinity, and mechanical properties of the composite material. By applying the optimized parameters in production, we can achieve consistent material properties and bond strength, while effectively monitoring and maintaining temperature, pressure, and time. The blog also covers advancements in process optimization and adaptation, such as the use of digital twin software for continuous product quality monitoring, AI models for data-driven adaptation of process parameters, and the development of more accurate physics-informed AI models to eliminate trial and error. Lastly, we provide resources for further exploration, including relevant literature, expert consultations, industry forums for knowledge sharing, and training resources for staff involved in the automated fiber placement process.