Composite Laminate Manufacturing and Characterization: A Comprehensive Review of Conventional Methods, AI Integration, Standardization Techniques, and Future Directions

Composite Laminates are now finding prominence in many high-performance industries. They offer a high strength-to-weight ratio, design flexibility, and strong resistance to environmental damage, making them superior to many traditional materials. This review examines the key factors that determine the strength and long-term durability of composite laminates and the integration of Artificial Intelligence (AI) to standardize the selection of process parameters in conventional manufacturing and characterization techniques. The discussion is structured into three main areas: failure mechanisms, advances in modeling and simulation, and standardized methods for material qualification and testing. The study summarizes current knowledge, points out research gaps, and outlines likely future directions. It emphasizes a shift from viewing composites as uniform materials to an application-focused approach that combines multi-scale physics models with data-driven machine learning. It also evaluates the role of standardized testing in ensuring reliability and addresses challenges such as barely visible impact damage and long-term fatigue. The final section predicts the future of composite design, including intelligent manufacturing, self-healing materials, and predictive analytics.