We have developed a robust, simulation-based optimization and control methodology to identify and implement the optimal curing conditions for thick-sectioned resin transfer molding (RTM)composite manufacturing. The global optimization of the process identified the need for at least one cooling stage within the cure cycle to produce quality laminates within a minimal amount of time. A sensitivity analysis in the variability of the model parameters within the simulation was performed to characterize its effect on an optimal cure cycle. To further account for observed batch to batch model parameter variability, a novel optimization algorithm based on Evolutionary Strategies was developed to identify a more robust cure cycle. The control strategy for implementing the optimal cure cycle relies solely on the use of non-intrusive heat flux sensors.
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