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

A control system for an automated manufacturing system, the control system comprising:

• a controller comprising:
• a processor;
• a memory device;
• and
• a non-transitory computer-readable medium storing instructions thereon that, when executed by the processor, cause the processor to perform steps comprising:
• receive measurements of properties of a composite sheet;
• receive historical properties of previously produced composite structures;
• receive a layup program including layup directions for a composite structure including multiple plies of the composite sheet and desired final dimensions of the composite structure;
• determine a predicted thickness of the composite structure based at least on the layup program, the measurements of the properties of the composite sheet, and the historical properties of the previously produced composite structures;
• compare the predicted thickness of the composite structure to the desired final dimensions of the composite structure;
• adjust the layup program until the predicted thickness of the composite structure is substantially the same as the desired final dimensions of the composite structure;
• and
• construct the composite structure according to the layup program as adjusted.