Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.

Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.

Abstract: Provided is a machine system having optical endpoint control and associated method for maintaining having is provided constant optical contact. Specifically, the machine system comprises a machine capable of movement in at least one direction. The machine is configured such that, during a calibration phase, a steerable retroreflective system is mounted upon the machine for movement therewith. A controller is configured to control the movement of the machine in at least one direction. The machine system may be configured to automatically adjust the feedrate of the machine, upon determining that a velocity required for the positioner to move the retroreflector to a desired position exceeds a certain segment feedrate threshold, such that an incident beam of light can maintain constant contact with the retroreflector throughout movement of the machine from the first position to the second position.

Abstract: A vacuum table for securing a sheet of material. The vacuum table includes a top plate that is porous, a perimeter vacuum chamber disposed beneath a perimeter of the top plate, and interior vacuum chambers bound by the perimeter vacuum chamber and disposed beneath a target area of the top plate that is inside the perimeter of the top plate.

Abstract: Provided is a machine system having optical endpoint control and associated method for maintaining having is provided constant optical contact. Specifically, the machine system comprises a machine capable of movement in at least one direction. The machine is configured such that, during a calibration phase, a steerable retroreflective system is mounted upon the machine for movement therewith. A controller is configured to control the movement of the machine in at least one direction. The machine system may be configured to automatically adjust the feedrate of the machine, upon determining that a velocity required for the positioner to move the retroreflector to a desired position exceeds a certain segment feedrate threshold, such that an incident beam of light can maintain constant contact with the retroreflector throughout movement of the machine from the first position to the second position.

Abstract: A method for machining a workpiece using a cutting tool attached to a spindle. The method comprises: (a) defining an initial tool path of the cutting tool relative to a workpiece using part definition data; (b) causing the cutting tool to cut along the defined initial tool path relative to the workpiece; (c) receiving sensor data representing machining process conditions during said cutting along the defined initial tool path; (d) processing the sensor data to determine a value of a machining process force parameter; and (e) causing the cutting tool to cut along a modified tool path relative to the workpiece such that the radial cutting depth changes and values of the machining process force parameter does not exceed a machining process force constraint. Operations (b) through (e) are performed by a computer system.

Abstract: Systems and methods are provided for evaluating performance of a projector. An imaging screen is configured to produce an image of a pattern projected thereon. A camera is configured to capture and digitize the image of the pattern projected on the imaging screen. An image analyzer is configured to receive the digitized image from the camera and to analyze the received digitized image.