Methods of forming a composite structure and associated automated manufacturing systems and components

An automated manufacturing system for controlling layup of a composite part, the automated manufacturing system comprising:

• a layup system configured to receive one or more fiber tows as an input material and lay up the one or more fiber tows to form a composite structure of one or more laid up plies;
• one or more sensors configured to measure properties of the one or more fiber tows while the layup system is feeding the one or more fiber tows to a substrate;
• and
• a controller configured to:
• receive the properties of the one or more fiber tows measured by the one or more sensors;
• receive external measured data associated with the properties of the one or more fiber tows, the external measured data including one or more of a matrix density, a matrix percentage, a fiber percentage, a matrix composition, or a surface roughness;
• compare the properties of the one or more fiber tows measured by the one or more sensors and the external measured data to historical data including data gathered from previous layup operations of composite parts;
• and
• adjust a feed-through of the one or more fiber tows during the layup, including adjusting a number of plies being laid up to compensate for a variation in the layup as provided by the properties of the one or more fiber tows measured by the one or more sensors during the layup.