Application Case: AFP-XS Flagship Compact Automated Fiber Placement System

General Introduction

The AFP-XS is Addcomposites’ flagship automated fiber placement system, positioned as a versatile, compact, and high-precision automation solution tailored to the R&D testing, small-batch production, and custom component manufacturing needs of composite materials. It is also currently the mainstream compact AFP equipment, with over 50 units installed worldwide. Featuring a compact structural design, the system integrates core capabilities such as high-precision placement, multi-process compatibility, and flexible deployment, thereby overcoming the limitations of traditional AFP systems—large footprint, high cost, and challenging installation—and making it well-suited for laboratory settings and small-to-medium-sized production workshops. The AFP-XS’s key advantage lies in its “small but refined” nature: the entire system is compact and lightweight, can be mounted on various collaborative and industrial robots, and requires no dedicated large-scale facility; at the same time, it delivers placement accuracy comparable to that of larger AFP systems, meeting the stringent precision requirements of R&D and small-batch production.

As the core product of Addcomposites, the AFP-XS seamlessly integrates automated fiber placement (AFP) with filament winding, enabling a single machine to perform both processes and significantly enhancing equipment utilization and process versatility. The system is equipped with the company’s proprietary AddPath software, which provides integrated functionality for path planning, simulation, and real-time monitoring, allowing R&D teams to rapidly translate design concepts into actual placement operations. Currently, the AFP-XS has been widely adopted by composite-material R&D institutions and small- to medium-sized manufacturers worldwide, serving as a key piece of equipment for innovative composite-material development and low-volume custom production. It spans multiple sectors, including aerospace, defense, marine, and materials research and development, thereby lowering the barriers to entry for enterprises and research organizations seeking to implement advanced composite-manufacturing technologies.

Working Principle

The AFP-XS operates by integrating two core technologies—automated fiber placement (AFP) and filament winding—underpinned by high-precision motion control. Combined with path-planning and simulation capabilities provided by a dedicated software system, it enables the precise forming of composite components while supporting real-time switching between the two processes. The system’s core architecture comprises a compact multi-tow placement head, switchable process modules, a motion-control module, the AddPath path-planning and simulation software, and an online inspection module. Prior to operation, operators import the component’s CAD model into the AddPath software, which automatically generates the optimal placement or winding path based on the component’s geometric features, material properties, and process requirements, and then conducts virtual simulations to validate the feasibility of the path and prevent interference and errors during actual manufacturing.

When the AFP process is employed, the system, based on the simulated toolpath, uses the motion-control module to drive the robot and its placement head. The tow-delivery module steadily conveys prepreg tows—supporting switching among 1-, 2-, and 4-tow configurations—to the placement head, while the heating unit preheats and activates the tows. Subsequently, the compaction rollers press the tows firmly against the mold surface, completing the fiber placement. During the placement process, the in-line inspection module continuously acquires real-time data on tow position, bonding status, and other parameters, which are fed back to the software system for dynamic adjustment. When a transition to the filament-winding process is required, no hardware changes are necessary; the process mode can be switched solely via software. The system then drives the mandrel to rotate, enabling the placement head to move axially and circumferentially along the mandrel axis, thereby achieving helical or hoop winding of the fibers and meeting the forming requirements for axisymmetric components.

Whether using the AFP process or fiber winding, the system features real-time tow cutting and restart capabilities, enabling precise tow segmentation according to path requirements and resuming layup or winding at designated locations to form complex geometric components. Upon completion of layup or winding, the software automatically records all process parameters, ensuring full traceability of production data and providing a solid foundation for subsequent process optimization and product quality analysis. The entire workflow—from design and simulation through execution to data traceability—is fully digitized.

Advantages and Key Features

As a flagship compact AFP system, the AFP-XS excels in process compatibility, deployment flexibility, precision control, and cost-effectiveness, while also incorporating a range of technological features tailored to the needs of R&D and small-batch production. Its most distinctive hallmark is dual-process compatibility: it is one of only a handful of compact systems worldwide that enable seamless switching between AFP and filament winding processes. This single machine can meet the forming requirements of various component types, significantly boosting equipment utilization and reducing capital expenditures for both industrial enterprises and research institutions. In terms of precision control, the system achieves a repeat positioning accuracy of ±0.05 mm, with highly accurate tape placement, thereby satisfying the stringent demands of R&D trials and custom components for dimensional accuracy and fiber orientation and ensuring consistent product performance.

Deployment flexibility is a key advantage of the AFP-XS. With its compact design, the system is small in size and lightweight, allowing it to be integrated onto various platforms such as collaborative robots and industrial robots. It does not require a dedicated large-scale production facility; it can be deployed in laboratories or small-scale manufacturing workshops. Moreover, the equipment is easy to install and commission, enabling rapid deployment and operation. The accompanying AddPath software provides end-to-end integration for design, simulation, job execution, and monitoring, featuring a user-friendly interface that allows R&D personnel to quickly complete path planning and simulation without requiring specialized programming skills, thereby significantly shortening the time from design to production. In terms of material compatibility, the AFP-XS supports a wide range of materials, including thermoset prepregs, thermoplastic prepregs, dry fibers, and tow-impregnated materials, allowing flexible switching based on R&D and production needs to meet the requirements of forming trials and small-batch production for different materials.

In addition, the AFP-XS offers excellent value for money: compared with conventional large-scale AFP systems, both procurement and operating costs are significantly reduced. It also supports a leasing model starting at €3,500 per month, thereby lowering the barrier to entry for small and medium-sized enterprises and research institutions seeking to adopt advanced composite manufacturing technologies. The system’s ease of maintenance is another notable advantage; its compact design simplifies the replacement of wear parts and routine upkeep, while Addcomposites provides global technical support to ensure stable equipment operation. In terms of digitalization, the system enables comprehensive data recording and traceability throughout the production process, providing robust data support for process optimization and product quality analysis and aligning with the evolving needs of digital manufacturing.

Application Areas and Use Cases

Leveraging its multifunctionality, compact footprint, and high precision, the AFP-XS is primarily deployed in applications such as composite-material R&D testing, small-batch custom production, and process validation, serving a wide range of sectors including materials research institutions, aerospace R&D centers, defense-related industries, shipbuilding and marine engineering, and small to medium-sized high-end manufacturing enterprises. In materials research institutions and universities, the AFP-XS is mainly used for studying forming processes of novel composite materials and for optimizing fiber placement and filament winding processes, thereby providing essential hardware support for new-material development. In aerospace R&D centers, it facilitates the prototyping and small-batch production of innovative spacecraft and aircraft components, enabling rapid translation of design concepts into physical parts and significantly shortening the R&D cycle. In the defense industry, it supports the small-batch fabrication of customized composite components for weapons and equipment, meeting the demands for lightweight construction and high performance. In the shipbuilding and marine sectors, it is employed for molding small, complex composite components, enhancing both the precision and efficiency of component production.

AFP-XS boasts a wealth of global application cases. Following its adoption by the French Compositadour institute, the system’s multi-material compatibility and seamless process-switching capabilities have enabled research into the layup of thermoset and thermoplastic materials as well as dry fibers. The system can rapidly switch between different materials and processes, significantly boosting R&D efficiency. Moreover, it integrates seamlessly with the institute’s existing humm3 equipment, thereby supporting the composite-material-process upgrades of local SMEs. In Finland, the IRMA institute employs AFP-XS for prototype manufacturing of composite materials and for the custom production of material-test components, deeming the system an intelligent, compact AFP processing tool. Its accompanying AddPath software is user-friendly, greatly simplifying layup programming and simulation workflows, and has become a core piece of equipment for the institute’s composite-material R&D. Meanwhile, Canada’s IND Group has selected AFP-XS to build a complete composite-manufacturing cell, believing it to be the only fiber-placement system that meets both its R&D needs and small-batch production requirements. From the very outset of the project, the system aligned perfectly with the group’s vision, and the manufacturing cell is now successfully used for the R&D and small-batch production of a wide range of composite components.