Title: Smart Roller: Real-Time Measurement Of Pressure Distribution At Nip Point Of Automated Fiber Placement Process

Authors: Charles Picciotto, Xiulun Yin, John Madden, Adam Clare, Anoush Poursartip

DOI:

Abstract: Automated Fiber Placement (AFP) is a highly complex manufacturing process that enables ‘lights out’ production of advanced composite components, and requires understanding of materials, design, and process planning to ensure the highest part quality. An important aspect of AFP is the tack between prepreg layers, governed by compaction pressure, temperature, and deposition speed. Prepreg tack is the primary mechanism that resists defect formation in composite layups, making precise control of the process parameters important to part quality. To support this need, this paper presents a Smart AFP Compaction Roller which measures, in realtime, the pressure distribution directly under the compaction roller as material is deposited. The Smart Roller is highly customizable in dimensions, mechanical compliance, and sensor arrangement, allowing it to be adapted to different AFP machines and operating conditions. An array of sensors embedded in the compaction roller provide real-time measurements of the pressure distribution across the compaction roller, providing a data stream which helps deepen the understanding of process-material interactions. Case studies are presented to illustrate how this data can be applied to balance rollers when installed on AFP equipment, identify process instabilities, and quantify prepreg tack. The results of these case studies demonstrate the potential of the Smart Roller to provide AFP users with insight to improve process reliability and part quality.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 142

Pages: 16

Price: $32.00