Abstract: A roller for automated fiber placement includes a flexible rim member arranged about a central axis. The flexible rim member has an inner side and an outer side, and the central axis is closer to the inner side than to the outer side. The roller also includes a hub member arranged substantially concentric with the flexible rim member about the central axis. The hub member defines an opening to receive a shaft of an automated fiber placement machine. The roller further includes a plurality of curved interconnect members extending between the hub member and the flexible rim member. Each of the plurality of curved interconnect members is elastically deformable to accommodate deformation of the flexible rim member. The roller also includes one or more roller skin layers coupled to the outer side of the flexible rim member.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller including a reflective layer that includes a reflective material dispersed in a polymeric material, and a light source positioned to project a beam of electromagnetic radiation proximate the compaction roller, the beam having a wavelength, wherein the reflective material has a reflectance of at least 80 percent at the wavelength.

Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller including a reflective layer that includes a reflective material dispersed in a polymeric material, and a light source positioned to project a beam of electromagnetic radiation proximate the compaction roller, the beam having a wavelength, wherein the reflective material has a reflectance of at least 80 percent at the wavelength.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller including a reflective layer that includes a reflective material dispersed in a polymeric material, and a light source positioned to project a beam of electromagnetic radiation proximate the compaction roller, the beam having a wavelength, wherein the reflective material has a reflectance of at least 80 percent at the wavelength.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.

Abstract: A composite wall assembly edge joint, includes a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet. The assembly further includes a composite flute core member, having a tapered first portion secured to the first tapered section; a second portion secured to the first composite face sheet; and a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.

Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: A composite wall assembly edge joint, includes a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet. The assembly further includes a composite flute core member, having a tapered first portion secured to the first tapered section; a second portion secured to the first composite face sheet; and a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section.

Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.

Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a compaction nip region, and a laser heating assembly including a laser that emits a beam of electromagnetic radiation and a scan head defining a scan field, the scan field being aligned with the compaction nip region, wherein the scan head scans the beam within the scan field.

Abstract: A fiber placement system including a compaction roller rotatable about an axis of rotation, the compaction roller including a reflective layer that includes a reflective material dispersed in a polymeric material, and a light source positioned to project a beam of electromagnetic radiation proximate the compaction roller, the beam having a wavelength, wherein the reflective material has a reflectance of at least 80 percent at the wavelength.