AI@FiberPlacement | Automated Fiber Placement (AFP) for the digital transformation

Efficient production of high-performance fiber composite structures

Initially used manual placement processes are increasingly being replaced by automated placement processes such as Automated Fiber Placement (AFP). One reason for this is the steadily growing volume in the production of components for aerospace applications. In addition, the currently emerging topic of »Urban Air Mobility« plays a role (e.g. RACER and BTfly). With a forecast of 100,000 passenger drones in 2050, production rates more reminiscent of the automotive industry will be required.

Automated Fiber Placement has the potential to significantly reduce manual manufacturing operations to enable appropriate economic and reproducible production at the required volume. The load-optimized automatic placement of reinforcing fibers is the key to the weight-optimized and cost-effective realization of high-performance fiber composite structures. In addition, production-related semi-finished product waste, which can amount to between 25 and 50 percent in conventional methods and processes depending on component complexity, can be significantly reduced in this way.  

Logo Federal Ministry of Education and Research
© Federal Ministry of Education and Research
Logo Federal Ministry of Education and Research
Sponsored by the Bavarian Ministry of Economic Affairs, Regional Development and Energy
© StMWi
Sponsored by the Bavarian Ministry of Economic Affairs, Regional Development and Energy
Co-funded by the European Union
© European Commission
Co-funded by the European Union

Automated data processing using artificial intelligence

Due to the large share of automation in these process technologies, the use of sensors and control actuators is unavoidable. In addition, there is the complete plant periphery and its influence on the process chain (ambient conditions, laying tools, etc.). Some of the resulting data is already collected and stored locally. This applies to the plant data (speeds, outputs, etc.) and the ambient conditions. Automatic further processing and the integration of the complete plant periphery is currently not widespread, but holds great potential for the holistic optimization of these manufacturing technologies and is thus the basis for the use of artificial intelligence (AI).

Use of Artificial Intelligence in Fiber Placement: Digital Twin in CAD Rendering
© Fraunhofer IGCV
Use of Artificial Intelligence in Fiber Placement: Digital Twin in CAD Rendering

Digitization of Automated Fiber Placement with intelligent process and quality monitoring for the digital twin

The subproject »AI@FiberPlacement« focuses on tapping the potential of AI within the robot-based and material-efficient fiber placement overall process chain. For this purpose, corresponding hardware requirements must be created in the area of plant and control technology as well as in the area of online process monitoring and the construction of new system architecture.

As a first step, the Coriolis Composites C1 system procured in the calendar year 2010 will therefore be completely replaced by a system of the latest generation. In addition, the course will be set for networking and digitizing the individual process steps (component design, manufacturing engineering, production, etc.) to create a digital component and plant twin.

New optimization areas are identified by merging the cross-process data and transferring it between the individual steps. This already starts with the component design, which directly influences the laying path planning and component architecture. Only by including all process and plant characteristics in the design a component design suitable for production can be created.

More interesting reference projects on this topic:


Development of scenarios for the cost-effective manufacture of substructures of a helicopter


Development of an efficient overall process chain for the production of integral thermoplastic composite aircraft frames


Automated variation and evaluation of composite components along their life cycle

From TRL2 to Take-off

Development of a CFRP manufacturing process chain (with Premium AEROTEC GmbH, among others) that enables significant weight and cost reductions compared with today's titanium construction methods.

AI Production Network Augsburg

New opportunities for regional industry

Cooperation with Fraunhofer IGCV

Contact us for an individual solution that suits your business needs.

Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles


We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.

Reference projects

To the overview of reference projects at Fraunhofer IGCV.