Abstract: An apparatus for forming a material layer onto a form tool may include at least one nosepiece configured to laterally sweep a ply carrier onto a form tool contour. The apparatus may include a pair of tension arms configured to support opposing lateral sides of a ply carrier having a material layer mounted to a lower surface thereof. The apparatus may include one or more actuators configured to position the tension arms during forming of the ply carrier to the form tool contour. The one or more actuators may be configured to sense and control lateral tension in the ply carrier during forming of the ply carrier to the form tool contour.

Abstract: A method and system of preparing a releasable underlying support for use in preparing a composite laminate is presented where a base tool is a covered with a conformable thin sheet on the tooling surface of a base tool, where the thin sheet is configured with one high tack surface side and an opposite side having a non-tack surface in contact with the tooling surface. The non-tack surface side will allow release of laid up pre-cure composite lamina that can then be cured on a separate curing tool. The thin sheet is positioned over the base tool and a vacuum source and sealed around the perimeter edge of the base tool. Drawing a vacuum causes the non-tack surface side of the film to be drawn downward into contact with the tooling surface. Plies of pre-cure lamina can then be added to the base tool covering and adhering to the high tack surface side.

Abstract: An apparatus for forming a material layer onto a form tool may include at least one nosepiece configured to laterally sweep a ply carrier onto a form tool contour. The apparatus may include a pair of tension arms configured to support opposing lateral sides of a ply carrier having a material layer mounted to a lower surface thereof. The apparatus may include one or more actuators configured to position the tension arms during forming of the ply carrier to the form tool contour. The one or more actuators may be configured to sense and control lateral tension in the ply carrier during forming of the ply carrier to the form tool contour.

Abstract: A method for initial separation of an adhered backing film from an uncured pre-impregnated composite lamina having an edge includes exposing and supporting the edge of the composite lamina, and applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.

Abstract: A method and system of preparing a releasable underlying support for use in preparing a composite laminate is presented where a base tool is a covered with a conformable thin sheet on the tooling surface of a base tool, where the thin sheet is configured with one high tack surface side and an opposite side having a non-tack surface in contact with the tooling surface. The non-tack surface side will allow release of laid up pre-cure composite lamina that can then be cured on a separate curing tool. The thin sheet is positioned over the base tool and a vacuum source and sealed around the perimeter edge of the base tool. Drawing a vacuum causes the non-tack surface side of the film to be drawn downward into contact with the tooling surface. Plies of pre-cure lamina can then be added to the base tool covering and adhering to the high tack surface side.

Abstract: A method for initial separation of an adhered backing film from an uncured pre-impregnated composite lamina having an edge includes exposing and supporting the edge of the composite lamina, and applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.