Composite manufacturing with a multi-dimensional array of independently-controllable thermal zones

A system and method 200 for manufacturing a composite structure 202 comprising a tool 204 with a surface 212 to support component elements of the composite structure. The surface is divided into a multi-dimensional array of thermal zones 216 to control the temperature of a component element (e.g. resin) of the composite structure. Sensors 206 provide data regarding a characteristic of the component element which is applied to a machine-learning algorithm 218 within a computing device 208 configured to generate control data to achieve a defined quality goal. A controller 210 independently controls the thermal zones 216 to locally heat, cool or maintain the temperature of the component element according to the control data to advance the component element or composite structure to the defined quality goal. This method is performed over a plurality of instances during which the machine-learning algorithm learns to increase advancement of the component element or composite structure to the defined quality goal. The algorithm may be configured to generate control data to achieve a desired shape of the front of the flow of resin, locally controlling the viscosity of the resin to steer the front of the flow into a desired shape or profile.