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Open AccessReview

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

German Aerospace Center (DLR e.V.), Institute of Composite Structures and Adaptive Systems, Department of Structural Mechanics, Lilienthalplatz 7, 38108 Braunschweig, Germany
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J. Compos. Sci. 2019, 3(2), 56; https://doi.org/10.3390/jcs3020056
Received: 28 March 2019 / Revised: 26 April 2019 / Accepted: 20 May 2019 / Published: 2 June 2019
The automated fiber placement process (AFP) enables the manufacturing of large and geometrical complex fiber composite structures with high quality at low cycle times. Although the AFP process is highly accurate and reproducible, manufacturing induced imperfections in the produced composite structure occur. This review summarizes and classifies typical AFP-related manufacturing defects. Several methodologies for evaluating the effects of such manufacturing defects from the literature are reviewed. This review paper presents recent scientific contributions and discusses proposed experimental and simulation-based methodologies. Among the identified ten defect classes, gaps and overlaps are predominant. This paper focuses then on methods for modelling and assessing gaps and overlaps. The state of the art in modelling gaps and overlaps and assessing their influence on mechanical properties is presented. Finally, research gaps and remaining issues are identified. View Full-Text
Keywords: review; automated fiber placement; AFP; manufacturing; defects; carbon-fiber reinforced plastics; composites review; automated fiber placement; AFP; manufacturing; defects; carbon-fiber reinforced plastics; composites
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Heinecke, F.; Willberg, C. Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement. J. Compos. Sci. 2019, 3, 56.

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