Abstract: A modular composite utility pole has a plurality of sections, each with a tapered hollow tube having a plurality of plies, wherein a first end has a larger diameter than a second end, wherein each section is adapted to join at least one adjoining section at a joint wherein the first end of an upper section overlaps the second end of a lower section, the lower section having a ledge proximate to the second end of the lower section, with a fastener passing through the joint via apertures in the sections, and wherein, when the modular composite utility pole is erected, the joint is self-located by the joint features, and wherein substantially all vertical load is transferred between sections via the a surface of the second end of the upper section resting upon the ledge of the lower section. Also disclosed are individual sections and methods of making them.

Abstract: A modular composite utility pole has a plurality of sections, each with a tapered hollow tube having a plurality of plies, wherein a first end has a larger diameter than a second end, wherein each section is adapted to join at least one adjoining section at a joint wherein the first end of an upper section overlaps the second end of a lower section, the lower section having a ledge proximate to the second end of the lower section, with a fastener passing through the joint via apertures in the sections, and wherein, when the modular composite utility pole is erected, the joint is self-located by the joint features, and wherein substantially all vertical load is transferred between sections via the a surface of the second end of the upper section resting upon the ledge of the lower section. Also disclosed are individual sections and methods of making them.

Abstract: A modular composite utility pole has a plurality of sections, each with a tapered hollow tube having a plurality of plies, wherein a first end has a larger diameter than a second end, wherein each section is adapted to join at least one adjoining section at a joint wherein the first end of an upper section overlaps the second end of a lower section, the lower section having a ledge proximate to the second end of the lower section, with a fastener passing through the joint via apertures in the sections, and wherein, when the modular composite utility pole is erected, the joint is self-located by the joint features, and wherein substantially all vertical load is transferred between sections via the a surface of the second end of the upper section resting upon the ledge of the lower section. Also disclosed are individual sections and methods of making them.

Abstract: Systems and methods for identifying foreign objects and debris (FOD) and defects during fabrication of a composite structure. The system includes at least one light source positioned to emit light that illuminates a portion of the composite structure with bright field illumination and that also illuminates another portion of the composite structure with dark field illumination. The bright field illumination is reflected differently by defects in the composite structure than from portions of the composite structure that are defect free. The dark field illumination is reflected differently by FOD on the composition structure than from surfaces of the composite structure that are FOD free. The system also includes at least one camera for receiving images of the illuminated portions of the composite structure. The images received by the camera may be processed by a processor which then outputs a response identifying defects and foreign objects and debris based on the images.

Abstract: A system and method for identifying defects in a composite structure is provided. The system includes a camera for receiving images of the composite structure, a processor for manipulating the images and outputting a response based on the images, and a light source for illuminating the composite structure. Advantageously, the light source is positioned at an oblique angle relative to the composite structure and comprises an infrared component that is differently reflected by defects in the composite structure than from portions of the composite structure that are defect free. Based on the response provided by the processor, defects that meet predetermined criteria can be identified.

Abstract: A composite material collation machine and associated method for fiber tape placement and consolidation at a relatively high rate are provided. The composite material collation machine includes a laser diode array for heating at least one fiber tape, a compaction device for pressing the fiber tape against a workpiece, an inspection system for monitoring the fiber tape, and a controller. The inspection system produces an output representative of at least one characteristic of the fiber tape, and the controller is capable of receiving the output and, based on the output, automatically altering at least one system parameter defining an operational characteristic of the composite material collation machine.

Abstract: A composite material collation machine and associated method for fiber tape placement and consolidation at a relatively high rate are provided. The composite material collation machine includes a laser diode array for heating at least one fiber tape, a compaction device for pressing the fiber tape against a workpiece, an inspection system for monitoring the fiber tape, and a controller. The inspection system produces an output representative of at least one characteristic of the fiber tape, and the controller is capable of receiving the output and, based on the output, automatically altering at least one system parameter defining an operational characteristic of the composite material collation machine.

Abstract: A composite material collation machine and associated method for fiber tape placement and consolidation at a relatively high rate are provided. The composite material collation machine includes a laser diode array for heating at least one fiber tape, a compaction device for pressing the fiber tape against a workpiece, an inspection system for monitoring the fiber tape, and a controller. The inspection system produces an output representative of at least one characteristic of the fiber tape, and the controller is capable of receiving the output and, based on the output, automatically altering at least one system parameter defining an operational characteristic of the composite material collation machine.

Abstract: A composite material collation machine and associated method for fiber tape placement and consolidation at a relatively high rate are provided. The composite material collation machine includes a laser diode array for heating at least one fiber tape, a compaction device for pressing the fiber tape against a workpiece, an inspection system for monitoring the fiber tape, and a controller. The inspection system produces an output representative of at least one characteristic of the fiber tape, and the controller is capable of receiving the output and, based on the output, automatically altering at least one system parameter defining an operational characteristic of the composite material collation machine.

Abstract: A system and method for identifying defects in a composite structure is provided. The system includes a camera for receiving images of the composite structure, a processor for manipulating the images and outputting a response based on the images, and a light source for illuminating the composite structure. Advantageously, the light source is positioned at an oblique angle relative to the composite structure and comprises an infrared component that is differently reflected by defects in the composite structure than from portions of the composite structure that are defect free. Based on the response provided by the processor, defects that meet predetermined criteria can be identified.