Abstract: A method for detecting a contaminant. A Fourier transform infrared scan for a section of the unconsolidated composite material is received in real time during manufacturing of the unconsolidated composite material by a composite material manufacturing system. A determination is made as to whether a contaminant is present in the section of the unconsolidated composite material in real time during manufacturing of the unconsolidated composite material by the composite material manufacturing system using the Fourier transform infrared scan and a machine learning model system trained to classify contaminants in unconsolidated composite materials using the Fourier transform infrared scan of the unconsolidated composite materials.

Abstract: A method, apparatus, system, and computer program product for detecting inconsistencies in an unconsolidated composite material. Fiber inconsistencies are detected in sections of the fibers input into a composite material manufacturing system in real time during operation of the composite material manufacturing system. Material inconsistencies are detected in the unconsolidated composite material in real time as the unconsolidated composite material is being manufactured by the composite material manufacturing system using the fibers. A determination is made as to whether the material inconsistencies are present in a number of the sections in which the fiber inconsistencies are detected in real time as the unconsolidated composite material is being manufactured by the composite material manufacturing system.

Abstract: A method, apparatus, system, and computer program product for manufacturing an unconsolidated composite material. Sensor data is received from a sensor system for a composite material manufacturing system, wherein the sensor data is received during manufacturing of the unconsolidated composite material by the composite material manufacturing system. A set of predicted properties is determined for a number of portions of the unconsolidated composite material as completed from manufacturing by the composite material manufacturing system using the sensor data. A quality level for the number of portions of the unconsolidated composite material is identified based on the set of predicted properties for the number of portions of the unconsolidated composite material.

Abstract: A system, apparatus, computer program product, and a method for manufacturing an unconsolidated composite material. Sensor data is received from a sensor system for a composite material manufacturing system. The sensor data is received during manufacturing an unconsolidated composite material by the composite material manufacturing system. A set of predicted properties is determined for a number of portions of the unconsolidated composite material using the sensor data. The set of predicted properties is for the number of portions of the unconsolidated composite material as a completed product. A corrective action is performed based on a quality level for the number of portions of the unconsolidated composite material.

Abstract: A method of manufacturing a composite structure includes accessing design data for the composite structure that is manufactured according to a process including forming a layup of plies of fibers using a machine tool. The method includes applying the design data to an ANN classifier to classify a localized inconsistency of a type of inconsistency on the composite structure, the localized inconsistency spatially referenced to a location on the composite structure. The method includes performing a root cause analysis to identify one or more of process parameters as a potential cause of the type of inconsistency, and modifying one or more of the geometric model, the layup design, or values of the one or more of the process parameters to address the potential cause.

Abstract: Methods and apparatus to increase fire resistance and fracture toughness of composite structures are described. An example multi-ply composite structure has at least eleven plies including an innermost ply forming a first external surface of the multi-ply composite structure, and an outermost ply forming a second external surface of the multi-ply composite structure, with the second external surface being located opposite the first external surface. The at least eleven plies further include at least one and no more than three fire-resistant plies positioned between the innermost ply and the outermost ply within either an innermost 33% of the at least eleven plies or an outermost 33% of the at least eleven plies. Respective ones of the fire-resistant plies include an epoxy-based resin and a first additive mixed into the epoxy-based resin. The first additive increases a flammability resistance of the multi-ply composite structure.

Abstract: Methods and apparatus to increase fire resistance and fracture toughness of composite structures are described. An example multi-ply composite structure has at least eleven plies including an innermost ply forming a first external surface of the multi-ply composite structure, and an outermost ply forming a second external surface of the multi-ply composite structure, with the second external surface being located opposite the first external surface. The at least eleven plies further include at least one and no more than three fire-resistant plies positioned between the innermost ply and the outermost ply within either an innermost 33% of the at least eleven plies or an outermost 33% of the at least eleven plies. Respective ones of the fire-resistant plies include an epoxy-based resin and a first additive mixed into the epoxy-based resin. The first additive increases a flammability resistance of the multi-ply composite structure.

Abstract: Methods and apparatus to increase fire resistance and fracture toughness of a composite structure are described. An example apparatus includes a composite structure formed by an innermost ply and a fire-resistant ply including a first additive to increase a flammability resistance of the structure, where the fire-resistant ply is an inner ply of the composite structure.

Abstract: Methods and apparatus to increase fire resistance and fracture toughness of a composite structure are described. An example apparatus includes a composite structure formed by an innermost ply and a fire-resistant ply including a first additive to increase a flammability resistance of the structure, where the fire-resistant ply is an inner ply of the composite structure.