Compaction-Pressure Regulation for Automated Fiber Placement of Advanced Polymer Composites Based on Simulation Planning and Closed-Loop Control Compensation

Automated fibre placement (AFP) is a key process for manufacturing advanced polymer–matrix composite aerostructures; however, an uneven compaction-pressure distribution of tows during lay-up reduces the inter-laminar bonding strength and induces processing defects such as bridging and wrinkles. In this study, a pressure regulation strategy coordinating simulation-based feed-forward planning with closed-loop feedback control is proposed as a modified processing route for improving the manufacturing quality of polymer composites. The strategy adopts a two-layer “planning–execution” architecture. In the planning layer, process parameters and placement trajectories are optimized in advance based on a compaction-roller pressure simulation model and a compaction-uniformity index. In the execution layer, closed-loop pressure control suppresses on-site disturbances in real time to ensure that the simulation objectives are realized, thereby achieving uniform control of the compaction-pressure field. Finally, multi-angle lay-up experiments were carried out on a convex-surface mould, and the pressure field was measured using pressure-sensitive films. The results show that the proposed regulation strategy improves pressure distribution uniformity by more than 6%, effectively enhancing curved-surface lay-up quality and the consolidation quality of advanced polymer composite components. This work provides an intelligent design-and-manufacturing route that links process simulation with real-time control for high-quality automated composite processing.