Abstract: An exemplary method of designing a manufacturing process comprises the steps of representing a workpiece as a plurality of triangular finite elements, representing the forming tools with mathematical equations which typically include cubic polynomials, simulating a deformation of the workpiece by the forming tools with a finite element model, wherein the finite element model is integrated with explicit integration. The method may be carried out with an apparatus which includes a memory device which stores a program including computer readable instructions, and a processor which executes the instructions. After the deformation of the workpiece has been simulated by the finite element model, the characteristics of the workpiece and forming tools can be modified to improve the final shape of the workpiece. After the finite element simulation produces an acceptable final workpiece shape, an actual workpiece can be formed with actual tools based on the simulation.

Abstract: A system and method for numerical control processing of an in-process part. A mathematical mapping is generated which approximates the deformation of the in-process part as measured against a nominal model. The mapping is applied to nominal NC tool paths to generate modified tool paths that travel in the distorted coordinate space of the in-process part. A result is that local features may be machined into the in-process parts in reasonable locations, and non contact measurement systems as well as surface finishing systems can travel at a more constant distance from the surface of the in-process part.

Abstract: A method for detecting misalignment of initially-aligned fiber filaments in a composite. An optical fiber is placed among the fiber filaments in the composite, light is directed into the optical fiber, the intensity of the light in the optical fiber is measured during subsequent composite processing, and attenuation in such light intensity is ascertained which indicates such misalignment (e.g., wrinkling, bending, buckling, porosity, delamination and the like) is being detected during such processing. In another preferred method, before-processing and after-processing x-ray images are taken of an x-ray-attenuating fiber which has been placed among x-ray-transparent fiber filaments in a composite.

Abstract: This invention discloses a system and method for measuring and monitoring three-dimensional shaped objects with projections of computer models of the objects. The computer models of the three-dimensional shaped objects are in the form of grid patterns. An image of the computer model of grid patterns is simultaneously projected from a dual projection system in two directions onto a real world instance of the object. Any variation between the computer model and the real world instance of the object is highlighted directly on the object by interference patterns of the two projections on the real world instance. The variation is quantified by counting the number of interference patterns on the real world instance of the object.

Abstract: A method for detecting misalignment of initially-aligned fiber filaments in a composite. An optical fiber is placed among the fiber filaments in the composite, light is directed into the optical fiber, the intensity of the light in the optical fiber is measured during subsequent composite processing, and attenuation in such light intensity is ascertained which indicates such misalignment (e.g., wrinkling, bending, buckling, porosity, delamination and the like) is being detected during such processing. In another preferred method, before-processing and after-processing x-ray images are taken of an x-ray-attenuating fiber which has been placed among x-ray-transparent fiber filaments in a composite.

Abstract: A system and method for precisely superimposing images of computer models in three-dimensional space to a corresponding physical object in physical space. The system includes a computer for producing a computer model of a three-dimensional object. A projector means projects an image of the computer model onto the physical object. A spatial transformation accurately maps the computer model onto a projection stage at the projector which projects a formed image in a three-dimensional space onto the physical object in a one-to-one correspondence.