Involving personnel having SBIR experience in other longer established awardee firms, the princopals of NextGen Materials and Processing are leveraging on previous work with automated fiber placement (AFP) of thin-ply composite materials, Utilizing a Design of Experiments approach, combined with analytical modeling, the effort is to identify the critical material, slitting, spooling, and AFP parameters that influence the repeatable, high quality laydown of thin-ply composite materials to produce large aerospace structures.