In the competitive landscape of aerospace manufacturing, the ability to produce complex composite components at scale while maintaining precision has become a defining factor for success. Traditional automated fiber placement systems have long forced manufacturers to choose between narrow tapes for complex geometries or wider tapes for faster production. The AFP-X system from Addcomposites challenges this paradigm through its innovative multi-width tape capability, offering a solution that adapts to varying production requirements without compromising aerospace-grade quality standards.

The AFP-X system revolutionizes composite manufacturing through its dual-configuration approach. The quarter-inch configuration employs four quarter-inch tows, enabling material deposition from 0.25 to 1 inch in width—ideal for intricate geometries with sharp corners, such as wing sections with demanding leading and trailing edges. Alternatively, the half-inch configuration utilizes four half-inch tows, depositing material from 0.5 to 2 inches in width, perfectly suited for larger components with gentler curves like fuselage sections.

The main key differentiator is that you end up having the possibility to start with half an inch but can go up to 2-inch width. This means you're able to run much larger parts much faster because you now have basically two extra capabilities of the machine—the flexibility to handle varying geometries and the speed to maximize throughput.

The true sophistication of AFP-X lies in its AddPath planning software, which serves as the system's intelligent brain. This software transforms complex layup requirements into optimized machine instructions, handling everything from automatic tape selection to course optimization. The system can automatically determine whether to use one, two, three, or all four tapes for each pass, selecting specific tape combinations based on geometry requirements.

The optimization is handled on the software side for the users. The operator just has to focus on what they want to plan, and they can assume that the software is taking care of the majority of things. This approach creates what I like to call "a symphony of tapes" placed around complex geometries, with all motion and actuation orchestrated seamlessly.

AFP-X employs multiple sophisticated systems to ensure that wider tape capability doesn't compromise precision. Each of the four tows features independent servo-based PID control for tension management, with separate feeding control and individual cutting mechanisms. This granular control ensures that whether running quarter-inch or half-inch tapes, each tow maintains optimal tension throughout the layup process.

The system's intelligent compaction strategy addresses complex geometries by sequencing the compaction process—pressing tapes on one side first, then the other. This unique approach, developed specifically for AFP-X, ensures complete adhesion even around sharp 90-degree corners where traditional systems might struggle.

Topology-optimized CFRP fuselage structure manufactured using AFP technology. (Credit: IFW, Leibniz University Hannover)

The production efficiency improvements with AFP-X follow an exponential curve. While initial setup and optimization for a large aerospace component might require two to three months, subsequent parts can be produced in as little as a day once processes are refined. The half-inch configuration can achieve approximately twice the production rate of quarter-inch systems for suitable geometries.

This dramatic improvement stems from multiple factors: doubled deposition rates with wider tapes, reduced material waste through optimized cutting strategies, and decreased operator complexity. By handling optimization at the software level, operators can focus on oversight and quality assurance rather than complex manual calculations, further streamlining the production process.

AFP-X ensures aerospace compliance through rigorous quality control measures. Both quarter-inch and half-inch tapes are slit from the same source material, maintaining consistent fiber and resin properties while adhering to the critical ±0.127mm slitting tolerance required for aerospace applications.

Because we are cutting the tape from the same material sheet at the end of the day, if you're slitting the quarter-inch or half-inch from the same material, your material is already compliant with the aerospace standard. This consistency ensures that regardless of tape width selected, the final component meets all necessary aerospace certifications and quality requirements.

The system incorporates cutting-edge laser scanner-based inspection capabilities, capturing real-time point cloud data for each course and utilizing machine learning models for gap and overlap detection. With support for field-of-view up to 50mm, the system can capture full tape width data, immediately alerting operators to any out-of-tolerance conditions.

For bridging prevention, AFP-X offers frame-by-frame verification capabilities. Operators can examine each point in complex geometries, adjusting frame density and tilt angles to ensure proper tape adhesion. This proactive approach eliminates potential issues before they occur, significantly reducing rework and scrap rates.

Choosing between configurations is a strategic decision based on component requirements. Quarter-inch systems excel for components with sharp corners, complex geometries, and applications requiring maximum steering capability—perfect for wing sections and intricate aerospace parts. Half-inch systems optimize production for large-scale components with gentler curves, high-volume scenarios, and applications where speed is paramount.

The moment you have a part, you want to have it simulated. The more preferred option is always going to be the half-inch one because it's higher volume, less cost operationally, and you have a higher volume of production—like two times the production rate. So why not choose the configuration that maximizes your efficiency while meeting your quality requirements?

The versatility of AFP-X shines in real-world applications. For fuselage sections, the half-inch configuration dramatically reduces layup time while maintaining surface quality. Wing sections benefit from the quarter-inch configuration's ability to navigate complex geometries around leading and trailing edges. The system's ability to switch between these configurations based on production requirements provides manufacturers with unprecedented flexibility.

The software's optimization capabilities extend beyond basic path planning, allowing operators to choose between prioritizing material savings or maximizing production speed. This flexibility enables manufacturers to adapt their approach based on specific project requirements, market demands, or material costs, ensuring optimal efficiency for each unique application.

The AFP-X system represents a paradigm shift in composite manufacturing, eliminating the traditional trade-off between speed and precision. With multi-width tape capability, intelligent software control, and robust quality assurance, manufacturers can achieve both exceptional throughput and aerospace-grade quality.

Ready to double your production rates while maintaining precision? Contact Addcomposites today for a personalized AFP-X demonstration and component simulation. Our experts will help determine your optimal configuration and showcase the efficiency gains possible with our technology.

Visit www.addcomposites.com to schedule your consultation and begin your journey toward faster, more efficient composite manufacturing.