Consolidation deformation suppression of composite gap/overlap by controlling fiber/resin flow during pressurization and heating

This study investigates methods to suppress consolidation deformation in gap and overlap regions between prepreg tows generated during Automated Fiber Placement (AFP). Inspired by the shape self-repair behavior during composite consolidation observed in the authors’ previous research, deformation suppression is explored through control of fiber/resin flow. Specifically, flow is promoted by modifying pressurization and heating cycles during autoclave curing, while an inverse approach is examined by suppressing flow through insertion of thin resin sheets into gap regions. The effectiveness of the proposed concepts is examined by cross-sectional thickness measurements after curing and by in-situ deformation monitoring using an embedded optical fiber shape sensor during consolidation. The influence of pressurization timing, heating profile, and material addition in gap regions on deformation behavior is discussed. These results suggest that controlling fiber/resin flow during consolidation can be an effective strategy for suppressing gap/overlap deformation and may offer practical pathways for improving AFP-manufactured composite quality.