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Volume 133
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Proceeding Paper

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

by
Beatriz Gomes
,
Sabela Sánchez
,
Mario Fernández-Pedrera
,
Prasad Shimpi
and
Pablo Romero-Rodríguez
*
AIMEN Technology Centre, Relva 27A-O Porriño, 36410 Pontevedra, Spain
*
Author to whom correspondence should be addressed.
†
Presented at the 15th EASN International Conference, Madrid, Spain, 14–17 October 2025.
Eng. Proc. 2026, 133(1), 73; https://doi.org/10.3390/engproc2026133073
Published: 6 May 2026
(This article belongs to the Proceedings of The 15th EASN International Conference on “Innovation in Aviation & Space Towards Sustainability Today & Tomorrow”)
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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.
Keywords: automated fiber placement (AFP); thermoplastic composites; real-time monitoring; temperature; interlaminar shear strength; crystallinity; porosity automated fiber placement (AFP); thermoplastic composites; real-time monitoring; temperature; interlaminar shear strength; crystallinity; porosity

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MDPI and ACS Style

Gomes, B.; Sánchez, S.; Fernández-Pedrera, M.; Shimpi, P.; Romero-Rodríguez, P. Thermal and Pressure Digital Twins from Online Process Control for Data-Based Optimization of Laser-Assisted In Situ Consolidation of High-Performance Composite Parts. Eng. Proc. 2026, 133, 73. https://doi.org/10.3390/engproc2026133073

AMA Style

Gomes B, Sánchez S, Fernández-Pedrera M, Shimpi P, Romero-Rodríguez P. Thermal and Pressure Digital Twins from Online Process Control for Data-Based Optimization of Laser-Assisted In Situ Consolidation of High-Performance Composite Parts. Engineering Proceedings. 2026; 133(1):73. https://doi.org/10.3390/engproc2026133073

Chicago/Turabian Style

Gomes, Beatriz, Sabela Sánchez, Mario Fernández-Pedrera, Prasad Shimpi, and Pablo Romero-Rodríguez. 2026. "Thermal and Pressure Digital Twins from Online Process Control for Data-Based Optimization of Laser-Assisted In Situ Consolidation of High-Performance Composite Parts" Engineering Proceedings 133, no. 1: 73. https://doi.org/10.3390/engproc2026133073

APA Style

Gomes, B., Sánchez, S., Fernández-Pedrera, M., Shimpi, P., & Romero-Rodríguez, P. (2026). Thermal and Pressure Digital Twins from Online Process Control for Data-Based Optimization of Laser-Assisted In Situ Consolidation of High-Performance Composite Parts. Engineering Proceedings, 133(1), 73. https://doi.org/10.3390/engproc2026133073

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