Abstract: Automated Fiber Placement (AFP) manufacturing with carbon fiber composites is increasingly used for complex and/or large structures. Computer-Aided Process Planning (CAPP) software supports process planning for AFP manufacturing to assist identifying optimal starting point location and layup strategy for each laminate ply. Ply optimization functions on measurement and scoring of geometry-based defects (gaps, overlaps, angle deviation, and steering). CAPP mitigates defect stacking through the laminate thickness by generating best ply scenarios and comparing ply defects to identify regions where defects are stacking up. Stacked defects frequency and severity are described using a disclosed scoring system, so process planners can craft fiber paths that mitigate the number and compounding effect of laminate geometry-based defects.