Abstract: The invention is a process and apparatus for forming structural members from layers of uncured composite material. The apparatus comprises a first station having at least one tape dispensing module, a second station where tape layers that have been deposited on a tool are vacuum treated in order to remove air entrapped between layers of the tape, and a track system which enables movement of the tool between the first and second stations as well as a tool storage station. The process of building the structural members comprises dispensing tape from each of the modules at the first station onto a tool, then removing entrapped air from between layers of deposited tape, then dispensing further layers of tape, then removing entrapped air, etc., until the desired tape configuration has been achieved. Until such built-up structural member is cured, it is stored in racks in the tool storage station. A unique "partial ply" module is disclosed for applying tape segments to the side forming surfaces of the tool.

Abstract: A method and apparatus for moving a first carrier tape in a first direction along a path, and a second tape toward the first tape, both in an incremental manner. After each increment of movement of the first tape, the second tape is advanced a proportional increment into overlying contact with the first tape. A press squeezes the first and second tape layers together, and a cutting mechanism is actuated to sever the overlying segment of second tape. The incremental movements of the first and second tapes are regulated so that the length of each second tape segment laid on the first tape is equal to the distance of travel of the first tape in the first direction. The direction of movement of the first tape is reversed so that at least one layer of second tape can be applied to the first tape.