Abstract: Disclosed herein is a duplicator assembly for forming a first void, which can be layered, in a laminated material of a part that matches a second void in a scarf repair guide. The duplicator assembly comprises an arm that comprises a first end portion and a second end portion. The first end portion is spaced apart from the second end portion. The duplication assembly also comprises a probe that is fixed to the first end portion of the arm and configured to trace the second void in the scarf repair guide. The duplication assembly further comprises a milling tool that is fixed to the second end portion of the arm such that the milling tool is co-movably coupled with the probe via the arm.

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: Disclosed herein is a duplicator assembly for forming a first void, which can be layered, in a laminated material of a part that matches a second void in a scarf repair guide. The duplicator assembly comprises an arm that comprises a first end portion and a second end portion. The first end portion is spaced apart from the second end portion. The duplication assembly also comprises a probe that is fixed to the first end portion of the arm and configured to trace the second void in the scarf repair guide. The duplication assembly further comprises a milling tool that is fixed to the second end portion of the arm such that the milling tool is co-movably coupled with the probe via the arm.