Optimization methods of carbon fiber composite antenna surface precision based on genetic algorithms

Abstract Carbon fiber composite materials are renowned for their exceptional properties, which meet the requirements for high‐precision antennas. Composite curing can cause deformation, resulting in antenna surface imperfections and reduced precision. As a result, most antennas are usually splice‐molded, and integral molding remains a challenge. This study aims to address the issue by optimizing the layup angle for antennas and proposing a new method for surface compensation. First, standard mathematical methods are used to determine the local fiber angle distribution within the unidirectional composite prepreg antenna, based on its geometric design. Next, the layup angle is optimized using a revised genetic algorithm for 10 different layups. Finally, a method for surface compensation is proposed to reduce surface errors. Reduction of up to 91.50% in surface error compared to the original surface. This study is expected to serve as a guide for the thin‐wall manufacturing of composite materials. Highlights Optimized layup angle for carbon fiber composite antenna manufacturing Genetic algorithm used to refine 10 different antenna layup configurations Proposed surface compensation method reduces errors by up to 91.50% Study provides a guide for thin‐wall composite material manufacturing.