Abstract: An electronically-controlled method is provided for manufacturing a ceramic matrix composite structure with a desired shape. The electronically-controlled method comprises processing at a first location a plurality of ceramic matrix composite plies to form a stack of the plurality of ceramic matrix composite plies. The electronically-controlled method also comprises transporting the stack of plurality of ceramic matrix composite plies from the first location to a second location which is remote from the first location. The electronically-controlled method further comprises processing at the second location the stack of plurality of ceramic matrix composite plies to provide the ceramic matrix composite structure with the desired shape.

Abstract: A method for developing a path plan for rollout compaction of a composite ply during composite manufacturing includes receiving ply parametric data based on characteristics of a ceramic matrix composite ply for placement on a layup tool and subsequent compaction using a compaction roller during the composite manufacturing and generating the path plan for automated manipulation of the compaction roller to compact the ceramic matrix composite ply on the layup tool based at least in part on the ply parametric data. A path planning development environment associated with the method includes at least one computing device with a processor and associated memory, a network interface, an application program storage device and a data storage device. Various examples of the method and the path planning development environment are disclosed.

Abstract: An electronically-controlled method is provided for manufacturing a ceramic matrix composite structure with a desired shape. The electronically-controlled method comprises picking a first ceramic matrix composite ply that is sandwiched between a first bottom backing film and a first top backing film, and peeling away the first bottom backing film from the first ceramic matrix composite ply. The electronically-controlled method also comprises placing the first ceramic matrix composite ply on a tool surface with the first top backing film facing away from the tool surface, and positioning a vacuum membrane against the first ceramic matrix composite ply that is on the tool surface to provide a vacuum-tight seal against the first ceramic matrix composite ply.

Abstract: A method includes steps of: (1) positioning an end effector relative to a ply of the ceramic composite material, wherein the end effector includes: a base; an arm that is coupled to and movable relative to the base; a base-gripper that is coupled to the base; and an arm-gripper that is coupled to the arm; (2) adhering the base-gripper to a first ply-portion of the ply; (3) adhering the arm-gripper to a second ply-portion of the ply; (4) moving the end effector relative to a forming-surface such that the first ply-portion of the ply is placed on a first surface-portion of the forming-surface; and (5) moving the arm relative to the base and to the forming-surface such that the second ply-portion is placed on a second surface-portion of the forming-surface, wherein the first surface-portion and the second surface-portion are non-coplanar.

Abstract: A method for operation of a layup cell during composite manufacturing includes running a compaction application program at a robot control system of the layup cell using a path plan data file defining a path plan for automated manipulation of a compaction roller for compacting a ceramic matrix composite ply on a layup tool, capturing image data of the ceramic matrix composite ply after compaction on the layup tool using a surface imaging device, at least temporarily storing the image data for the ceramic matrix composite ply after compaction in a ply image data file and processing the ply image data file to identify one or more areas of the ceramic matrix composite ply that require re-compaction. The layup cell includes the layup tool, the ceramic matrix composite ply, the robot control system, a robotic arm and at least one end effector.

Abstract: A method for cleaning a ceramic matrix from a compaction roller includes steps of: (1) applying a cleaning fluid to the compaction roller; (2) scrubbing the compaction roller to remove ceramic particles of the ceramic matrix from a compaction-roller surface of the compaction roller, and (3) drying the compaction roller to remove the cleaning fluid from the compaction-roller surface.

Abstract: Methods for developing a path plan for rollout compaction of a composite ply during composite manufacturing include: selecting a working path plan data file from a working path plan repository, running a path adaptation application program to access compaction history data files in a compaction history repository relating to the working path plan data file and to identify an inconsistency in the compaction history data files that is not resolved in the working path plan data file and generating a path adaptation for the working path plan data file based on the inconsistency that is not resolved to form an adapted path plan data file defining an adapted path plan that includes the path adaptation. Additional methods include using path plans for compaction on the layup tool, capturing image data and processing the image data to build and/or add to the compaction history data file.

Abstract: A method for compacting a ceramic composite material includes steps of: (1) positioning a roller in contact with a ply-surface of a ply of the ceramic composite material, wherein the ply is positioned on a compaction-surface; (2) applying a compaction pressure to the ply using the roller such that the contact pressure is substantially uniformly distributed on the ply; and (3) with the roller in contact with the ply-surface and applying the compaction pressure, moving the roller across the ply to conform the ply to the compaction-surface.

Abstract: A method for manufacturing a ceramic matrix composite structure includes steps of: (1) picking up a ply of a ceramic matrix composite material at a staging location; (2) removing a bottom backing layer from the ply at a backing-removal location; (3) placing the ply on a forming surface at a forming location after removing the bottom backing layer; (4) compacting the ply on the forming surface; (5) removing a top backing layer from the ply after compacting the ply on the forming surface; and (6) inspecting the ply after compacting the ply on the forming surface.

Abstract: A method of detecting defects in a composite layup includes capturing, using an infrared camera, reference images of a reference layup being laid up by a reference layup head. The method also includes manually reviewing the reference images for defects, and generating reference defect masks indicating defects in the reference images. The method further includes training, using the reference images and reference defect masks, a neural network, creating a machine learning model that, given a production image as input, outputs a production defect mask indicating the defect location and the defect type of each defect. The method also includes capturing, using an infrared camera, production images of a production layup being laid up by the production layup head, and applying the model to the production images to automatically generate a production defect masks indicating each defect in the production images.

Abstract: A composite forming apparatus includes an end effector, a forming feature, and a non-contact heater. The forming feature is coupled to the end effector. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or a prior formed composite ply. The non-contact heater heats to a portion of the composite ply before the portion of the composite ply is formed over the forming tool or the prior formed composite ply.

Abstract: A manufacturing system includes a plurality of rails, a plurality of head manipulating mechanisms respectively coupled to the rails, and a plurality of automated fiber placement (AFP) heads respectively coupled to the head manipulating mechanisms. The rails are arranged around a barrel-shaped layup tool, and each rail is parallel to a tool axis. Each head manipulating mechanism moves along a rail. The head manipulating mechanisms position the AFP heads in circumferential relation to each other about a tool surface of the layup tool. A total quantity of AFP heads comprises the maximum number of AFP heads that can be circumferentially arranged in longitudinal alignment with each other on the layup tool without interfering with each other while applying layup material over the tool when the layup tool is stationary and during rotation about the tool axis, to thereby fabricate a green state layup having a barrel shape.

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, apparatus, system, and computer program product for designing a composite hollow body. A computer system selects ply layers for the hollow composite body. The ply layers comprise courses having course edges. The computer system positions the course edges between the ply layers throughout the hollow composite body to create a staggering of the course edges between the ply layers for a design of the hollow composite body.

Abstract: There is provided a method that includes directing one or more infrared cameras at a compaction roller of a composite laying head of a composite layup machine. The one or more infrared cameras are mounted aft of the compaction roller. The method includes applying heat to a substrate by a heater. The heater is mounted forward of the compaction roller. The method further includes using the one or more infrared cameras, to obtain one or more infrared images of the compaction roller, during laying down of one or more composite tows of a composite layup onto the substrate by the compaction roller. The method further includes identifying, based on the one or more infrared images, one or more temperature profiles of the compaction roller, and analyzing identified temperature profiles, to determine one or more of, a layup quality of the composite layup, and a heat history of the composite layup.

Abstract: A manufacturing system includes a plurality of rails, a plurality of head manipulating mechanisms respectively coupled to the rails, and a plurality of automated fiber placement (AFP) heads respectively coupled to the head manipulating mechanisms. The rails are arranged around a barrel-shaped layup tool, and each rail is parallel to a tool axis. Each head manipulating mechanism moves along a rail. The head manipulating mechanisms position the AFP heads in circumferential relation to each other about a tool surface of the layup tool. A total quantity of AFP heads comprises the maximum number of AFP heads that can be circumferentially arranged in longitudinal alignment with each other on the layup tool without interfering with each other while applying layup material over the tool when the layup tool is stationary and during rotation about the tool axis, to thereby fabricate a green state layup having a barrel shape.

Abstract: A composite forming apparatus includes an end effector, a forming feature, and a non-contact heater. The forming feature is coupled to the end effector. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or a prior formed composite ply. The non-contact heater heats to a portion of the composite ply before the portion of the composite ply is formed over the forming tool or the prior formed composite ply.

Abstract: There is provided a method that includes directing one or more infrared cameras at a compaction roller of a composite laying head of a composite layup machine. The one or more infrared cameras are mounted aft of the compaction roller. The method includes applying heat to a substrate by a heater. The heater is mounted forward of the compaction roller. The method further includes using the one or more infrared cameras, to obtain one or more infrared images of the compaction roller, during laying down of one or more composite tows of a composite layup onto the substrate by the compaction roller. The method further includes identifying, based on the one or more infrared images, one or more temperature profiles of the compaction roller, and analyzing identified temperature profiles, to determine one or more of, a layup quality of the composite layup, and a heat history of the composite layup.

Abstract: A method of detecting defects in a composite layup includes capturing, using an infrared camera, reference images of a reference layup being laid up by a reference layup head. The method also includes manually reviewing the reference images for defects, and generating reference defect masks indicating defects in the reference images. The method further includes training, using the reference images and reference defect masks, a neural network, creating a machine learning model that, given a production image as input, outputs a production defect mask indicating the defect location and the defect type of each defect. The method also includes capturing, using an infrared camera, production images of a production layup being laid up by the production layup head, and applying the model to the production images to automatically generate a production defect masks indicating each defect in the production images.

Abstract: A composite manufacturing system is provided. The composite manufacturing system comprises a fiber placement head, a compaction roller associated with the fiber placement head, and a temperature regulation system associated with the compaction roller. The temperature regulation system is configured to actively control a temperature of the compaction roller. The temperature regulation system comprises a number of temperature sensors, a cooling system, and a controller. The number of temperature sensors are configured to detect the temperature of the compaction roller. The cooling system is associated with the compaction roller and is configured to cool the compaction roller. The controller is in communication with the number of temperature sensors and the cooling system. The controller is configured to cool the compaction roller such that the temperature is below a threshold temperature.