Published: March 2026
Estimated reading time: 5 minutes
Mikrosam has successfully commissioned a robotic Automated Fiber Placement (AFP) work cell at Qarbon Aerospace, marking a significant step forward in the industrialization of thermoplastic composite manufacturing for aerospace applications.
The installation is designed to strengthen Qarbon Aerospace’s research and technology (R&T) capabilities while preparing the company for the next phase of high-rate, automated composite production. As aircraft manufacturers continue to push for lighter, stronger, and more efficiently produced structures, systems like this AFP work cell are becoming central to future manufacturing strategies.
A strategic upgrade for thermoplastic composite manufacturing
The newly deployed AFP system is part of Qarbon Aerospace’s broader effort to advance thermoplastic processing technologies, including:
- induction welding
- advanced structural integration
- ice protection systems such as HELIOS
Unlike traditional thermoset composites, thermoplastics offer faster processing, recyclability potential, and improved toughness. However, they also demand precise temperature control, accurate fiber placement, and repeatable processing conditions—all areas where AFP systems provide clear advantages.
By integrating Mikrosam’s robotic AFP solution, Qarbon is positioning itself to:
- accelerate development cycles
- reduce qualification risk
- enable scalable production of advanced composite structures
LIBRA-series AFP system: flexibility meets precision
At the core of the installation is Mikrosam’s LIBRA-series AFP machine, engineered to support multiple material systems and complex geometries.
Key capabilities include:
Multi-material AFP head
- Supports thermoset, thermoplastic, and dry fiber UD prepreg tapes
- Enables flexible manufacturing across different composite programs
Advanced heating technologies
- Laser heating with multi-point temperature monitoring
- Fast thermal camera integration for thermoplastic consolidation
- Infrared heating for thermoset processing
Closed-loop process control
- Maintains consistent tow tension during placement
- Ensures precise deposition and material consolidation
Quality Control System (QCS)
- Real-time monitoring of process parameters
- Full traceability aligned with aerospace certification requirements
MikroPlace software platform
- Offline programming and simulation
- Optimized production planning and reduced setup time
Future-ready architecture
- Automated head exchange capability
- Compatibility with wider tapes
- Upgrade pathways for evolving production needs
This level of system integration reflects a broader industry shift toward digitally controlled, software-driven composite manufacturing environments.
Designed for complex aerospace structures
The AFP work cell was customized to meet Qarbon Aerospace’s specific requirements, particularly for producing complex, high-performance thermoplastic parts.
Its ability to handle intricate geometries while maintaining consistent thermal and mechanical conditions is critical for aerospace-grade components. The system’s:
- closed-loop thermal control
- precise fiber placement
- reduced material waste
directly address key challenges in scaling thermoplastic composites from lab-scale development to industrial production.
Strengthening partnerships: materials meet automation
A notable aspect of this deployment is Qarbon Aerospace’s collaboration with Toray, a global leader in advanced composite materials.
The AFP system will process Toray Cetex thermoplastic prepregs and UD tapes, known for:
- consistent fiber alignment
- optimized resin distribution
- suitability for large structural components
- compliance with aerospace OEM specifications
This integration of high-performance materials with advanced automation is essential for achieving both performance and manufacturability at scale.
According to industry stakeholders, combining AFP automation with advanced thermoplastic materials can:
- eliminate secondary processing steps
- shorten production cycles
- reduce overall manufacturing costs
Enabling next-generation aerospace programs
The installation is not just a technology upgrade—it is a strategic investment aligned with future aerospace program requirements.
Qarbon Aerospace aims to leverage this capability to support:
- commercial aircraft programs
- defense applications
- emerging advanced air mobility platforms
The AFP work cell enables rapid prototyping and validation of new materials and processes, while also laying the groundwork for transitioning R&T into production-ready solutions.
This dual-use capability—supporting both development and scalable manufacturing—is becoming increasingly important as aerospace programs demand faster innovation cycles.
Industry context: AFP as a cornerstone of composite automation
The deployment of robotic AFP systems like Mikrosam’s reflects a broader transformation across the composites industry.
Key trends driving AFP adoption include:
- increasing composite content in aircraft structures
- demand for lightweight, fuel-efficient designs
- need for repeatable, high-quality production processes
- shift toward thermoplastic composites for faster manufacturing
AFP technology addresses these requirements by enabling:
- precise fiber orientation control
- reduced material waste
- consistent part quality
- automation of complex layup processes
As a result, AFP is evolving from a niche aerospace tool into a core manufacturing platform for advanced composites.
The bottom line
Mikrosam’s AFP work cell installation at Qarbon Aerospace highlights how automation, materials science, and digital manufacturing are converging to reshape composite production.
By combining:
- robotic AFP technology
- advanced thermoplastic materials
- real-time process control
- scalable system architecture
Qarbon Aerospace is positioning itself at the forefront of next-generation composite manufacturing.
As aerospace programs continue to demand higher production rates, lower costs, and improved performance, investments in flexible and high-precision systems like AFP will play a critical role in defining the industry’s future.