Automated tape layup, is predisposed to positioning defects like gaps and overlaps which are detrimental to the structural integrity of the part. This work investigates the details of the design of inline width control concept, a technique for inline control of consolidated tape width to eliminate gaps. Continuous inline width variation is achieved by online control of the compaction force, during the layup process. Successful calibration and benchmarking tests using standard pressure measurement sensors are presented. Performance assessment tests are performed which demonstrate online variation of force from 50 N to 1000 N, having a standard deviation of 10 N. Correlation models for width control are obtained and it is shown that a width increase of 5–50 % of initial width is achievable using the prototype. An example of linearly varying force resulting in a trapezium shaped consolidated tape is also shown as a part of the feasibility study.