Abstract: A system to fabricate a composite item includes an end effector, robotic vehicle, sensor, and cutting system. The end effector applies a course to a layup form. The robotic vehicle positions the end effector. The sensor senses an edge of a previously applied course. The cutting system cuts a profile on the course in response to the sensed edge.

Abstract: To apply a plurality of courses on a layup form to fabricate a composite item, a first course of the plurality of courses is applied on the layup form along a first path. A second path is determined that overlaps an edge of the first course by a predetermined minimum overlap distance. The edge is sensed. A profile is cut along a second course of the plurality of courses to correspond to the sensed edge. The second course is applied on the layup form along the second path.

Abstract: An optical laser guidance system includes a laser sensor, a controller and a plurality of actuators. The laser sensor detects a projected laser beam and sends an electrical signal representative of the position of the laser beam to the controller. The controller interprets the representative signal and uses the position of the laser beam relative to a predetermined reference position to generate a control signal to control an actuator in order to control the direction of travel of a vehicle or robot with respect to a predetermined guidepath. The laser sensor may also receive additional control messages that result in the controller generating additional control signals to control additional actuators in order to perform additional functions. The optical laser guidance system may also include a laser projection system capable of projecting a two- or three-dimensional guidepath and additional control messages.