Abstract: Disclosed herein is a method of repairing a contoured composite structure. The method includes applying a first facesheet, a core layer, and a second facesheet onto a contoured composite structure to form a repair tool. The method further includes removing the repair tool from the contoured surface of the contoured composite structure. After removing the repair tool from the contoured surface of the contoured composite structure, the method includes replacing a structural abnormality of a contoured composite structure with an uncured repair structure. The method also includes applying the repair tool onto the contoured composite structure such that the repair tool overlays the uncured repair structure. The method additionally includes curing the uncured repair structure when the repair tool is applied onto the contoured composite structure over the uncured repair structure.

Abstract: Systems and methods for actualizing simulated scarfing and patching for repair of composite laminates. A virtual environment is provided that enables engineers to optimize a repair design and provide the most robust repair solution that meets structural requirements, while minimizing the material removal and the impact to the composite structure. An optimization algorithm is configured to adjust contour offsets for pad-up plies and adjust scarf taper ratios in any direction to reduce the amount of material removed or avoid underlying structures. Scarf repair designs are subsequently transmitted to repair technicians for manual scarfing via printed templates or automated/robotic scarfing using converted computer-readable code. The technology also provides digital data for automated repair ply cutting.

Abstract: Systems and methods for actualizing simulated scarfing and patching for repair of composite laminates. A virtual environment is provided that enables engineers to optimize a repair design and provide the most robust repair solution that meets structural requirements, while minimizing the material removal and the impact to the composite structure. An optimization algorithm is configured to adjust contour offsets for pad-up plies and adjust scarf taper ratios in any direction to reduce the amount of material removed or avoid underlying structures. Scarf repair designs are subsequently transmitted to repair technicians for manual scarfing via printed templates or automated/robotic scarfing using converted computer-readable code. The technology also provides digital data for automated repair ply cutting.