Global warming drives innovation in aerospace materials, with thermoplastic composites offering recyclability and compatibility with automated manufacturing. This study proposes a methodology to translate optimized variable stiffness laminate (VSL) designs into manufacturable geometries. A two-level clustering process based on thickness and principal stresses, followed by genetic algorithm optimization, is applied to a beam structure. Results show feasibility of automatic zone definition but reveal misalignment with load paths and increased weight in final designs. While limitations remain, the approach provides a foundation for refining VSL design methodologies and advancing their practical use in aerospace applications.