Data-Driven Optimization of Discontinuous and Continuous Fiber Composite Processes Using Machine Learning: A Review

Abstract

This paper surveys the application of machine learning in fiber composite manufacturing, highlighting its role in adaptive process control, defect detection, and real-time quality assurance. First, the need for ML in composite processing is highlighted, followed by a review of data-driven approaches-including predictive modeling, sensor fusion, and adaptive control-that address material heterogeneity and process variability. An in-depth analysis examines six case studies, among which are XPBD-based surrogates for RL-driven robotic draping, hyperspectral imaging (HSI) with U-Net segmentation for adhesion prediction, and CNN-driven surrogate optimization for variable-geometry forming. Building on these insights, a hybrid AI model architecture is proposed for natural-fiber composites, integrating a physics-informed GNN surrogate, a 3D Spectral-UNet for defect segmentation, and a cross-attention controller for closed-loop parameter adjustment. Validation on synthetic data-including visualizations of HSI segmentation, graph topologies, and controller action weights-demonstrates end-to-end operability. The discussion addresses interpretability, domain randomization, and sim-to-real transfer and highlights emerging trends such as physics-informed neural networks and digital twins. This paper concludes by outlining future challenges in small-data regimes and industrial scalability, thereby providing a comprehensive roadmap for ML-enabled composite manufacturing.