Ply Surface Modeling and Path Planning for Automated Fiber Placement of Complex Composite Structures With Large and Variable Thickness

ABSTRACT A ply surface modeling and path planning approach is presented to reduce placement defects in complex composite structures with large and variable thickness. The mechanisms of thickness‐induced defects are analyzed through mathematical modeling. An algorithm based on the fast marching method (FMM) is developed to generate ply surfaces for complex‐geometry components with large and variable thickness. This ply surface modeling is integrated with a mesh‐based path planning algorithm designed to minimize defects on thick and variable‐thickness structures. Simulation and experimental results confirm significant improvements: automated fiber placement (AFP) trials on a spar show that 45° ply gaps decrease from 3.21 to 1.45 mm, satisfying tolerance requirements, and all wrinkle defects are eliminated. This work provides an effective solution for low‐defect AFP manufacturing of complex, thick composite components.