AbstractAutomated Fiber Placement (AFP) enables precise deposition of thermoplastic tapes oncomplex geometries, however variations in temperature, compaction pressure, depositionspeed, and tooling conditions can affect the final laminate quality. This study presents anintegrated real-time monitoring system and a systematic methodology for process/productdata analysis linking process parameters to mechanical and microstructural performance.Mechanical testing evaluation by interlaminar shear strength (ILSS), thermal analysis, andmicroscopy studies identified both the consolidation and mold temperatures as the criticalparameters for optimized mechanical properties. Results showed ILSS above 45 MPa,crystallinity up to 37.9%, and minimal porosity (~1%). Digital tools developed provided fulltraceability, early instability detection, and continuous optimization, enhancing reliabilityand repeatability in high-performance thermoplastic composite manufacturing, whichpaves the way towards zero-defect manufacturing.