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The resin transfer molding (RTM) process was adopted for composite manufacturing for high volume production net shape structural parts using low viscosity thermoset resins and continuous fibers. This chapter discusses how to overcome the challenges of RTM, which has led to many variations that have sprung over the last two decades to fill a niche need. The part quality manufactured using RTM varies due to the effects of inherent variations in the materials and process parameters. The following important issues that manifest themselves either during fiber preforming or mold filling stages of RTM have been identified and discussed: racetracking channels, deformation of fiber structure during draping, macrovoid formation, microvoid formation, transverse flow in the thickness direction and dual scale fiber structure in a preform. One can address and overcome them with process modeling, control and automation …