Abstract: A composite placement machine has a simplified fiber delivery path from a creel to a lay-up table. A carriage is mounted for motion in the Y-axis along the length of an overhead beam. A composite placement head having a shiftable compaction roller is supported by the carriage. A stationary creel at one end of the overhead beam forms a band of composite material having a width that extends in the X-axis. A lay-up table is mounted for motion in the X-axis and rotary motion about a C-axis that is perpendicular to the X and Y-axes. The motion of the head in the Y-axis, the shiftable compaction roller, and the motion of the lay-up table X-axis and the C-axis allows the head to apply composite material to the lay-up table in both Y-axis directions in any orientation without twisting the band of composite material relative to the X and Y-axes.

Abstract: A composite placement machine has a simplified fiber delivery path from a creel to a lay-up table. A carriage is mounted for motion in the Y-axis along the length of an overhead beam. A composite placement head having a shiftable compaction roller is supported by the carriage. A stationary creel at one end of the overhead beam forms a band of composite material having a width that extends in the X-axis. A lay-up table is mounted for motion in the X-axis and rotary motion about a C-axis that is perpendicular to the X and Y-axes. The motion of the head in the Y-axis, the shiftable compaction roller, and the motion of the lay-up table X-axis and the C-axis allows the head to apply composite material to the lay-up table in both Y-axis directions in any orientation without twisting the band of composite material relative to the X and Y-axes.

Abstract: A process uses predictive modeling software for selectively applying relief cuts and tension to the fibers in a 2-dimensional panel prior to shaping the panel into a 3-dimensional part. The predictive modeling software identifies areas of fiber tension in the final molded product, and relief cuts are made in those areas. The plies are loaded into grippers attached to a supporting frame and predictive modeling software is used to identify areas of fiber compression in the final molded product. Tension is applied to the identified areas of fiber compression. The panel is molded in a form and cure press, and the tension is maintained on the material while closing the mold halves. The molded part is able to conform to the final mold shape without tearing in areas of tension and without material buildup in areas of compression in the final molded part or post mold distortion.

Abstract: A method of forming a reinforced pressure vessel includes the steps of providing a thin wall cylinder, wrapping the cylinder with at least one layer of prepreg reinforcing fiber, wrapping the cylinder with at least one layer of perforated shrink tape, applying heat to the shrink wrapped cylinder to squeeze the at least one prepreg fiber layer to force resin to weep through the perforated shrink tape and cure the resin, and allowing the resin to remain on the outer surface of the shrink tape to form a protective layer on the pressure vessel.

Abstract: A method for molding a composite structure includes the steps of infusing a fabric with a resin to form a ply of composite material, transferring the ply of composite material to a preheat station, and preheating the ply of composite material to a temperature that renders the composite material more drapable, but is less than a temperature that causes the resin in the material to initiate polymerization. The ply of composite material is then transferred to a press station where it is heated to a temperature that causes the resin to initiate polymerization, whereby the curing time for the composite material is substantially less than the curing time of a fabric that is infused with an epoxy resin.