DLR uses Aibuild software to combine AFP and 3D printing for in situ bonding of PEEK on TPC laminates

The German Aerospace Center (DLR) has demonstrated a hybrid manufacturing process that combines automated fiber placement (AFP) with 3D printing, using Aibuild’s software platform to manage the workflow. The process achieves in situ bonding of 3D-printed PEEK onto thermoplastic composite (TPC) laminates, eliminating a separate consolidation step. Aibuild’s software imports surface scans of the AFP-laid laminate, aligns the print path, and generates conformal slicing for printing directly onto and around complex geometries. The work was published by CompositesWorld on May 18, 2026, and represents a practical integration of two additive processes under a single digital thread.

This partnership matters because it addresses a persistent gap in hybrid manufacturing: the software layer that coordinates AFP and material extrusion. Most AFP systems and 3D printers operate on separate control architectures, forcing manual alignment and limiting design freedom. Aibuild’s ability to ingest surface scan data and produce conformal toolpaths for printing onto non-planar substrates directly expands the design envelope for thermoplastic composite structures. For Aibuild, this is a credible reference in the aerospace composites segment, where DLR’s validation carries weight. The application targets lightweight, high-temperature structures for aircraft and space, where PEEK-on-TPC bonding could reduce fastener count and assembly time. The work also aligns with the broader trend of combining additive and subtractive or forming processes under unified software orchestration.

For Aibuild, the practical next step is to productize the workflow demonstrated by DLR into a commercially available module, likely targeting AFP system integrators and aerospace tier-1 suppliers. The key execution risk is not technical feasibility but workflow integration: AFP systems from different OEMs have proprietary control interfaces, and Aibuild will need to build or partner for those connectors. Users evaluating hybrid AFP-3D printing should ask whether the software supports their specific AFP platform and whether the in situ bond strength meets their qualification requirements.