AFP Defect Characterisation
The Importance of Testing Scale and Defect Interaction †
Leith Afilal (TU Delft - Aerospace Engineering)
Daniël Peeters (TU Delft - Aerospace Engineering)
John Alan Pascoe (TU Delft - Aerospace Engineering)
René Alderliesten (TU Delft - Aerospace Engineering)
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Abstract
Automated Fibre Placement (AFP) enables the rapid and precise manufacturing of composite structures, but the process inherently introduces defects such as gaps and overlaps, which can significantly affect structural performance. Most existing studies assess these effects through coupon-scale testing; however, such an approach may not capture the influence of structural scale and defect interaction. This study investigates the combined effects of specimen dimension and defect configuration on stiffness, strength, and damage evolution. Two characteristic defect patterns were examined—aligned and staggered gaps—across two specimen dimensions. The results reveal different scaling trends for strength and stiffness between the two configurations. They also show the influence of specimen size on damage initiation and delamination behaviour. The findings demonstrate that coupon-based knockdowns cannot be directly extrapolated to structural components without accounting for defect interaction and scale effects.
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