Abstract: Aspects of the present disclosure include various exemplary methods relating to composite lamination using one or more arrays of parallel material dispensing heads. In one example, a method of fabricating a high aspect ratio composite article is disclosed which may involve applying a first strip material to a work surface datum at a first angle with a first material dispenser, and applying a plurality of second strip materials to a work surface datum each at a second angle with a plurality of rotatable parallel material dispensers. The method may also involve advancing the first material dispenser and the rotatable parallel material dispensers as a unit the width of the second strip material and continuing application of the first strip material by the first material dispenser and a plurality of second strip materials by the rotatable parallel material dispensers until a desired length is reached.

Abstract: A method comprises forming a composite layup, including dispensing fiber material; and monitoring the dispensed material prior to laydown for a marker. The marker provides information about an upstream location of the material. The forming further includes using the information in the marker to adjust material course length to control where the upstream location will be deposited, if at all.

Abstract: The feed rate of an ultrasonic knife used to cut composite material is optimized using adaptive control. One or more parameters such as ultrasonic power or side load on the knife is sensed and used to generate feedback control signals. The feedback control signals are used to optimize the commanded feedrate of the knife.

Abstract: Systems and methods for avoidance of tape flaw or splices in manufacturing are disclosed. In one embodiment, a method of applying a tape onto a workpiece includes feeding the tape from a tape supply using a tape application assembly, and applying the tape onto the workpiece using the tape application assembly. Simultaneously with the feeding of the tape, the tape is monitored for a marker indicating a defect within the tape, the marker being spaced apart along the tape from the defect such that the marker arrives prior to the defect. The method further includes detecting the marker, and avoiding the application of a portion of the tape that includes the defect onto the workpiece.

Abstract: To fabricate a composite item, a first end effector is selected from a plurality of end effectors to apply tows to a form. The first end effector includes an integrated creel configured to store spools of the tow on an assembly of spindles. The assembly of spindles is substantially parallel to a longitudinal axis of the first integrated creel. The first end effector is secured to a positioning device. The tows are applied to the form and the tows are compacted on the form with a compaction device. The assembly of spindles are disposed circumferentially about the compaction device.

Abstract: In one embodiment, an apparatus for removing scrap from tape material on original backing paper includes a supply reel, at least one cutting member, at least one heating member and/or cooling member, and at least one removal member. The supply reel is for supplying and unrolling tape material on original backing paper. The at least one cutting member is for cutting unrolled tape material while on original backing paper. The at least one of a heating member and a cooling member are for at least one of heating and cooling cut unrolled tape material on original backing paper. The at least one removal member is for removing scrap cut unrolled tape material from original backing paper.

Abstract: The feed rate of an ultrasonic knife used to cut composite material is optimized using adaptive control. One or more parameters such as ultrasonic power or side load on the knife is sensed and used to generate feedback control signals. The feedback control signals are used to optimize the commanded feedrate of the knife.

Abstract: In one embodiment, an apparatus for removing scrap from tape material on original backing paper includes a supply reel, at least one cutting member, at least one heating member and/or cooling member, and at least one removal member. The supply reel is for supplying and unrolling tape material on original backing paper. The at least one cutting member is for cutting unrolled tape material while on original backing paper. The at least one of a heating member and a cooling member are for at least one of heating and cooling cut unrolled tape material on original backing paper. The at least one removal member is for removing scrap cut unrolled tape material from original backing paper.

Abstract: To fabricate a composite item, a first end effector is selected from a plurality of end effectors to apply tows to a form. The first end effector includes an integrated creel configured to store spools of the tow on an assembly of spindles. The assembly of spindles is substantially parallel to a longitudinal axis of the first integrated creel. The first end effector is secured to a positioning device. The tows are applied to the form and the tows are compacted on the form with a compaction device. The assembly of spindles are disposed circumferentially about the compaction device.

Abstract: A composite item is fabricated with a device. The device includes and end effector and a positioning device. The end effector places a tow. The end effector includes a spindle, compaction device, and a path. The spindle detachably secures a spool of tow and the path is disposed from the spool to the compaction device. The positioning device positions the end effector. The end effector is detachably secured to the positioning device.

Abstract: Systems and methods for avoidance of tape flaw or splices in manufacturing are disclosed. In one embodiment, a method of applying a tape onto a workpiece includes feeding the tape from a tape supply using a tape application assembly, and applying the tape onto the workpiece using the tape application assembly. Simultaneously with the feeding of the tape, the tape is monitored for a marker indicating a defect within the tape, the marker being spaced apart along the tape from the defect such that the marker arrives prior to the defect. The method further includes detecting the marker, and avoiding the application of a portion of the tape that includes the defect onto the workpiece.

Abstract: A composite item is fabricated with a device. The device includes and end effector and a positioning device. The end effector places a tow. The end effector includes a spindle, compaction device, and a path. The spindle detachably secures a spool of tow and the path is disposed from the spool to the compaction device. The positioning device positions the end effector. The end effector is detachably secured to the positioning device.

Abstract: Aspects of the present disclosure include various exemplary embodiments of systems and methods relating to composite lamination using one or more arrays of parallel material dispensing heads. In one embodiment, a method of fabricating a high aspect ratio composite article generally includes applying a first strip material to a work surface datum at a first angle with a first material dispenser, and applying a plurality of second strip materials to a work surface datum each at a second angle with a plurality of rotatable parallel material dispensers. The method also includes advancing the first material dispenser and the rotatable parallel material dispensers as a unit the width of the second strip material and continuing application of the first strip material by the first material dispenser and a plurality of second strip materials by the rotatable parallel material dispensers until a desired length is reached.