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AbstractThe resin transfer molding (RTM) manufacturing process consists of either of two considerations. The first is the fluid flow analysis where tracking of the flow fronts are of primary importance, and the second is the combined multidisciplinary flow/thermal analysis, where kinetics and cure need to be accounted for in the process modeling stages. In the combined multidisciplinary flow/thermal analysis, viscosity is a function of temperature. The so-called continuous sensitivity formulations are developed for the latter case of non-isothermal process modeling of composites manufactured by RTM to predict, analyze, and optimize the manufacturing process. Attention is focused on developments for non-isothermal process modeling simulations, and numerical illustrative examples are presented for the sensitivity analysis of structural composites manufactured by RTM.