Abstract: An illustrative example of the present disclosure provides a machine configured to form a composite structure. The machine includes a composite placement machine, measuring equipment, a tool path generator, and compaction equipment. The composite placement machine lays up composite plies. The measuring equipment measures surfaces of the composite plies to form measurements during layup of the composite plies. A computer includes a model of the composite plies for a structure. The tool path generator forms a modified tool path based upon a difference between the measurements and expected measurements for the composite plies in the model.

Abstract: A method for analyzing a surface quality of a laminate part including the steps of creating a planned dimensioned representation of a laminate part desired to be built which includes a first surface having a first topography; placing fibers into locations for the laminate part desired to be built; and curing a resin associated with the placed fibers fabricating an as-built laminate part which includes a second surface having a second topography which corresponds to the first surface having the first topography. The method also includes aligning the first surface, the second surface and the locations of the fibers; determining a first elevation of a first point on the first surface and a second elevation of a second point on the second surface; and observing the first surface, the second surface and the locations of the fibers in alignment and the first elevation relative to the second elevation in analyzing the surface quality of the laminate part.

Abstract: An illustrative example of the present disclosure provides a method. A first set of composite plies including a first outer ply of a first composite structure is laid up. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.

Abstract: A method and apparatus for forming a composite object. A first plurality of tows is laid up over a tool according to a first path. A second plurality of tows is laid up over the tool according to a second path. A first portion of the first plurality of tows runs non-parallel to a second portion of the second plurality of tows. First ends of the first portion of the first plurality of tows and second ends of the second portion of the second plurality of tows meet at a merge zone along the tool to form a ply of a composite laminate.

Abstract: A process and system for improving surface quality of composite structures, including laying up a first set of composite plies including a first outer ply of a first composite structure. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.

Abstract: Systems and methods are provided for dynamically managing heater position for an Automated Fiber Placement (AFP) machine. One embodiment is a method that includes retrieving distance data indicating predicted distances of a heating surface of a heater of the AFP machine to a surface of a laminate being laid-up by the AFP machine, for each of multiple locations along a path. The method also includes directing the AFP machine to lay up the laminate in accordance with a Numerical Control (NC) program, identifying a current location of the heater in the path, determining a speed at which the heater of the AFP machine is moving, correlating the current location of the heater with a predicted distance, and adjusting an amount of power for the heater at the current location based on the predicted distance that was correlated with the current location, and the speed at the current location.

Abstract: A method and system for forming a composite laminate. A layup plan is generated for laying up a plurality of plies having a plurality of merge zones, each ply of the plurality of plies having a corresponding merge zone at which ends of a first plurality of tows for each ply and ends of a second plurality of tows for each ply meet. The locations of the plurality of merge zones are offset relative to each other through a thickness of the composite laminate. The plurality of plies is then laid up according to the layup plan to form a composite laminate.

Abstract: A method and system for forming a composite laminate. A layup plan is generated for laying up a plurality of plies having a plurality of merge zones, each ply of the plurality of plies having a corresponding merge zone at which ends of a first plurality of tows for each ply and ends of a second plurality of tows for each ply meet. The locations of the plurality of merge zones are offset relative to each other through a thickness of the composite laminate. The plurality of plies is then laid up according to the layup plan to form a composite laminate.

Abstract: A method and apparatus for forming a composite object. A first plurality of tows is laid up over a tool according to a first path. A second plurality of tows is laid up over the tool according to a second path. A first portion of the first plurality of tows runs non-parallel to a second portion of the second plurality of tows. First ends of the first portion of the first plurality of tows and second ends of the second portion of the second plurality of tows meet at a merge zone along the tool to form a ply of a composite laminate.

Abstract: An illustrative example of the present disclosure provides a method. A first set of composite plies including a first outer ply of a first composite structure is laid up. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.

Abstract: A method for analyzing a surface quality of a laminate part including the steps of creating a planned dimensioned representation of a laminate part desired to be built which includes a first surface having a first topography; placing fibers into locations for the laminate part desired to be built; and curing a resin associated with the placed fibers fabricating an as-built laminate part which includes a second surface having a second topography which corresponds to the first surface having the first topography. The method also includes aligning the first surface, the second surface and the locations of the fibers; determining a first elevation of a first point on the first surface and a second elevation of a second point on the second surface; and observing the first surface, the second surface and the locations of the fibers in alignment and the first elevation relative to the second elevation in analyzing the surface quality of the laminate part.

Abstract: Systems and methods are provided for dynamically managing heater position for an Automated Fiber Placement (AFP) machine. One embodiment is a method that includes retrieving distance data indicating predicted distances of a heating surface of a heater of the AFP machine to a surface of a laminate being laid-up by the AFP machine, for each of multiple locations along a path. The method also includes directing the AFP machine to lay up the laminate in accordance with a Numerical Control (NC) program, identifying a current location of the heater in the path, determining a speed at which the heater of the AFP machine is moving, correlating the current location of the heater with a predicted distance, and adjusting an amount of power for the heater at the current location based on the predicted distance that was correlated with the current location, and the speed at the current location.

Abstract: Systems and methods are provided for dynamically managing heater position for an Automated Fiber Placement (AFP) machine. One embodiment is a method that includes retrieving distance data indicating predicted distances of a heating surface of a heater of the AFP machine to a surface of a laminate being laid-up by the AFP machine, for each of multiple locations along a path. The method also includes directing the AFP machine to lay up the laminate in accordance with a Numerical Control (NC) program, identifying a current location of the heater in the path, determining a speed at which the heater of the AFP machine is moving, correlating the current location of the heater with a predicted distance, and adjusting an amount of power for the heater at the current location based on the predicted distance that was correlated with the current location, and the speed at the current location.

Abstract: Systems and methods are provided for dynamically managing heater position for an Automated Fiber Placement (AFP) machine. One embodiment is a method that includes retrieving distance data indicating predicted distances of a heating surface of a heater of the AFP machine to a surface of a laminate being laid-up by the AFP machine, for each of multiple locations along a path. The method also includes directing the AFP machine to lay up the laminate in accordance with a Numerical Control (NC) program, identifying a current location of the heater in the path, determining a speed at which the heater of the AFP machine is moving, correlating the current location of the heater with a predicted distance, and adjusting an amount of power for the heater at the current location based on the predicted distance that was correlated with the current location, and the speed at the current location.