Steering for in-situ AFP-manufactured structures: Part 2 - Optimized layup strategy

Thermoplastic Automated Fiber Placement (AFP) steering enables the fabrication of complex curved structures, but requires careful control of tape geometry to avoid defects. This paper details a methodology for constant curvature steering based on an empirical model characterizing tape deformation during in-situ AFP. A corresponding path planning algorithm leverages this model to generate defect-free steered plies. The approach was experimentally validated for both half-inch and quarter-inch tapes, demonstrating robustness across different process parameters and material combinations. Results show that quarter-inch tape offers a wider design space for steering applications than half-inch tape. By combining the critical arc length concept introduced in Part 1 of this work with steering-optimized path planning, this paper establishes a framework for process-optimized layup strategies to manufacture high-quality in in-situ AFP structures. • Extension of critical arc length model for quarter-inch tape. • High resolution optical analysis of steered tape geometries. • Development of data-based model for layup strategy to avoid gaps between steered tapes. • Foundation laid for process-optimized manufacturability of curved parts.