Review on defect detection, characterization and process optimization in automated fiber placement of aviation composite

As an important method for efficient manufacturing of advanced composites, Automated Fiber Placement (AFP) technology has exhibited significant advantages in the production of large and complex curved structures in the aerospace field. However, due to the limitations in equipment precision, material characteristics, and structural complexity, various types of layup defects are prone to occur during the AFP process, which severely affect the structural performance and service reliability. Accordingly, research on key technologies such as defect detection, characterization, and process optimization has become essential for improving AFP manufacturing quality. This study briefly discusses the foundational research pertaining to typical defects in the AFP processes. Current research progress in defect detection, characterization, and process parameter optimization in AFP technology is systematically reviewed. Existing limitations in detection, characterization, and process optimization methods for AFP defects are summarized, along with future research directions. Based on the findings of the relevant research, a closed-loop technical framework for composite manufacturing quality control is proposed, providing a systematic reference for achieving high-quality, high-reliability, and high-intelligent AFP manufacturing of composites.