Abstract: Automated fiber placement (AFP) cutter blade assemblies, AFP cutter systems including the same, and associated methods. An AFP cutter blade assembly includes a blade base and a reversible blade insert configured to be coupled to the blade base in either of a first cutter blade configuration, in which a first cutting edge is an active cutting edge, and a second cutter blade configuration, in which a second cutting edge is the active cutting edge. In examples, an AFP cutter system includes a plurality of AFP cutter blade assemblies in combination with an actuator assembly. In examples, a method of reconfiguring a reversible blade insert of an AFP cutter blade assembly includes uncoupling the reversible blade insert from a blade base, rotating the reversible blade insert relative to the blade base, and operatively coupling the reversible blade insert to the blade base in a different configuration.

Abstract: An illustrative embodiment of the present disclosure provides a method of forming a composite structure. Composite material is placed into a cavity of a mold. A layup support is placed over the cavity. A number of composite plies is laid up over the layup support, the composite material, and the cavity.

Abstract: Automated fiber placement (AFP) cutter blade assemblies, AFP cutter systems including the same, and associated methods. An AFP cutter blade assembly includes a blade base and a reversible blade insert configured to be coupled to the blade base in either of a first cutter blade configuration, in which a first cutting edge is an active cutting edge, and a second cutter blade configuration, in which a second cutting edge is the active cutting edge. In examples, an AFP cutter system includes a plurality of AFP cutter blade assemblies in combination with an actuator assembly. In examples, a method of reconfiguring a reversible blade insert of an AFP cutter blade assembly includes uncoupling the reversible blade insert from a blade base, rotating the reversible blade insert relative to the blade base, and operatively coupling the reversible blade insert to the blade base in a different configuration.

Abstract: An illustrative embodiment of the present disclosure provides a method of forming a composite structure. Composite material is placed into a cavity of a mold. A layup support is placed over the cavity. A number of composite plies is laid up over the layup support, the composite material, and the cavity.

Abstract: A cutting apparatus including a cutting blade configured to slide along a surface of an anvil to cut tow material. The cutting blade includes a first bottom face portion and a cutting edge. The cutting blade further includes a second bottom face portion positioned between the first bottom face portion and the cutting edge. The first bottom face portion is configured to contact the surface of the anvil when the cutting blade slides along the surface to cut the tow material. The second bottom face portion and the cutting edge are located above the first bottom face portion such that the second bottom face portion and the cutting blade are free of contact from the surface when the cutting blade slides along the surface to cut the tow material.

Abstract: A cutting apparatus including a cutting blade configured to slide along a surface of an anvil to cut tow material. The cutting blade includes a first bottom face portion and a cutting edge. The cutting blade further includes a second bottom face portion positioned between the first bottom face portion and the cutting edge. The first bottom face portion is configured to contact the surface of the anvil when the cutting blade slides along the surface to cut the tow material. The second bottom face portion and the cutting edge are located above the first bottom face portion such that the second bottom face portion and the cutting blade are free of contact from the surface when the cutting blade slides along the surface to cut the tow material.