Automated Fiber Placement

Automated Dynamics' proprietary, industry proven technologies for the fabrication of thermoset and thermoplastic composite structures are integrated into every machine sold. Our knowledge and experience with composite structure manufacturing assures the correct process parameters to meet each application's cost and performance requirements.

It's a Matter of Geometry

Automated Fiber Placement (AFP) is traditionally used on very complex surfaces and smaller structures and utilizes single or multiple narrow, slit tapes or tows to make up a given total prepreg band width.  This is typically the case within Automated Dynamics as well, but we have taken some liberties with the definition when it improves the Customer's automation solution. The Automated Fiber Placement Process is depicted to the left. In both thermoset and thermoplastic processing, incoming tape is electrically heated using nitrogen. Prepreg material application and consolidation or debulk is always achieved through a compaction roller medium that may be heated or cooled.

The need for individual tows or a single wide band should always be a compromise between part surface geometry and manufacturing throughput. Complex geometries that demand complex fiber placement are typically approached by the industry with multiple 0.125 inch – 0.250 inch (3.18 mm – 6.35 mm) tows. While this solution usually conquers the geometry challenge, it adds to machine complexity and cost and increases manufacturing time. A compromising approach, geometry dependent, may be to utilize multiple 0.500 inch (12.77 mm) tapes to improve throughput, while still maintaining good laminate quality on the complex surface. Automated Dynamics’ Fiber Placement Heads are designed with a given total bandwidth in mind that allows internal material handling components to be tailored to individual tape widths that can sensibly be placed against the part surface as efficiently as possible.

Our Proprietary Thermoplastic Process

Our in-situ and preform thermoplastic processes often utilize only one slit tape, but we still refer to this technology as Fiber Placement. The single tape may be as wide as 2.000 inches (50.80 mm), but we consider this to be narrow for the traditional Tape Laying nomenclature. Typical for thermosetting systems, but unavailable elsewhere for thermoplastic processing, Automated Dynamics builds mutli- 0.250 inch (6.35 mm) tape head systems for both in-situ consolidation and preforming applications. We have both single cut and individual tow control capabilities. Further explanation of the specific material matrix processes and advantages can be viewed by clicking thermoset or thermoplastic.

All head technologies are modular, have modular subassemblies for convenience of cleaning and change-out, and are supported by our easy-to-use software.

Advantages of Our Equipment:

• Reduced labor costs
• Reduced material scrap
• Right-sized to fit your specific application(s)
• Automation means acceptable ROI
• Reduced manufacturing space
• Reduced manufacturing time
• Automatic debulking of thermoset prepreg
• In-situ consolidation of thermoplastic prepreg
• Increased material throughput
• Improved composite structure quality
• Precise, repeatable, tension-independent process enables placement at any angle
• User-friendly proprietary off-line and on-line software
• Training and support packages tailored to fit Customers' needs

View our Photo Gallery & Video Library for customer examples.

Automated Tape Laying

We offer the unique combination of composite materials expertise, processing experience and automated machine design necessary to develop cost-effective composite processes and processing equipment for the fabrication of high quality composite structures.

One Single Tape

Automated Tape Laying (ATL) utilizes a single, wide, unidirectionally reinforced, slit tape to layup simple, gentle contours or flat parts. This is typically the case within Automated Dynamics as well, but we have taken some liberties with the definition when it improves the Customer's automation solution. The need for individual tows or a single wide band should always be a compromise between part surface geometry and manufacturing throughput. Simple geometries over large surface areas are typically approached by the industry with wide 6.000 inch — 12.000 inch (152.40 mm — 304.80 mm) tape. While this solution may adequately handle the overall simple geometry, localized pad-ups and occlusions may still demand hand laid up or prekitted plies and hand trimming on the part surface. Complex ATL systems with "flying knife" technology may trim to a perfect edge of ply (EOP), but the scrap generated must be deposited off the part or removed by hand. This precise EOP capability seems attractive, but it adds to machine complexity and cost and increases manufacturing time. It may be wise to consider a tailored approach using multiple wide tapes, perhaps 1.000 inch (25.40 mm), to approximate the EOP while maintaining higher throughput and reducing scrap.

Our Tailored Approach

Automated Dynamics provides tailored ATL equipment with 3.000 inch — 12.000 inch (76.20 mm — 304.80 mm) bandwidths that handle unidirectional prepregs, fabric prepregs, and film materials. A trimming head may be integrated to trim the outer EOP prior to tooling the part for the cure cycle.

Our in-situ and preform thermoplastic processes often utilize only one slit tape, but we still refer to this technology as Fiber Placement. The single tape may be as wide as 2.000 inches (50.80 mm), but we consider this to be narrow for the traditional Tape Laying nomenclature. Typical for thermosetting systems, but unavailable elsewhere for thermoplastic processing; Automated Dynamics builds mutli- 0.250 inch (6.35 mm) tape head systems for both in-situ consolidation and preforming applications. Please click thermoset or thermoplastic for specific material processing information.

All head technologies are modular, have modular subassemblies for convenience of cleaning and change out, and are supported by our easy-to-use software.

Advantages of Our Equipment:

• Reduced labor costs
• Reduced material scrap
• Right-sized to fit your specific application(s)
• Automation means acceptable ROI
• Reduced manufacturing space
• Reduced manufacturing time
• Automatic debulking of thermoset prepreg
• In-situ consolidation of thermoplastic prepreg
• Increased material throughput
• Improved composite structure quality
• Precise, repeatable, tension-independent process enables placement at any angle
• User-friendly proprietary off-line and on-line software
• Training and support packages tailored to fit Customers' needs

View our Photo Gallery & Video Library for specific customer examples of Automated Tape Laying

Contact Automation

Contact Automated Dynamics to learn how we can help you find an affordable, automated solution to your high performance composite needs.

Joshua Trombley
Schenectady, NY
518.377.6471 x275
jtrombley@automateddynamics.com

Software & Services

Automated Dynamics offers software and services in order to provide a complete solution to your composite manufacturing requirements. Like all of our products, software and service packages are tailored to meet a customer's specific needs. Each client's level of expertise is different; therefore clients are offered as little or as much assistance as needed, adding to the affordability and ease-of-use of our products.

Software

Automated Dynamics' software is essential to the success of your project. The Windows® interface provides ease-of-use for our proprietary software suite: offline FPM© (Fiber Placement Manager) and online FPS© (Fiber Placement Software). FPM© is bundled with SolidWorks© to offer maximum user flexibility. The user may develop the part surface in SolidWorks© directly or import the surface geometry as an IGES, STEP or other CAD translation. Third party translators may also be implemented, depending on part complexity. Ply orientation, reference curves, boundaries for occlusions and pad-ups, steered bands, and many other selectable tools are all typical programmable details. Multiple robot configurations may be established in the database for the factory floor with multiple AFP and ATL machine installations. The programmer needs only to choose the workcell to generate a part file for that particular machine using a single set of ply data. In addition, an individual machine can host multiple head configurations. Again, the user needs only to choose the appropriate process head for a specific geometry. All software is password and security protected per the client's specific needs. Updates and upgrades are available with an annual service contract.

Services

We service, support and provide training for over fifty machines in sixteen countries. Automated Dynamics will develop a service package to support your company from first discussions to final production and throughout the life of your equipment. Service contracts are tailored to include as little or as much support as needed. Contracts can be extended and added throughout the life of the equipment. The following options are just a few of the services that can be a part of your successful R&D or production manufacturing program:

• Generate accurate simulation of fiber paths and associated part fabrication time
• Training of your employees at our New York site and at your facility
• Service and support at your facility
• Phone and online support
• Five in-house machines for demonstration, prototyping, and process & product development

View our Photo Gallery & Video Library for customer examples.

Thermoplastic Processing

Automated Dynamics' experience in the fabrication and use of thermoplastic tape placement workcells involves the integration of the proprietary Automated Dynamics thermoplastic fiber placement head and our patented hot gas torch (HGT) heating system with commercially available or custom built robotic equipment or gantry systems. This equipment is used to place and simultaneously consolidate continuous fiber reinforced thermoplastic unidirectional tape or tow onto a tool surface, through user-developed part programs, to provide high performance composite structures. We use carbon and glass continuous fiber reinforcement in a wide variety of engineering grade thermoplastic resin systems such as PEEK, PPS, PEI, PA, PP, PE, PFA and others. We have provided engineered thermoplastic composite solutions for many complex problems. Our technology is optimized to make a wide variety of shapes and sizes including tubes, cones, flat laminates, convex or concave surfaces, box beams, and complex changing geometries.

Compared to thermoset prepreg, thermoplastic prepreg is considerably easier to handle in an automated system. The tape form is stiff and "boardy" at typical ambient conditions, therefore an enclosed feed chamber with active cooling is not required. Resin transfer is not an issue, but component wear is, so hard surface finishes are required on contact parts such as guide chutes. All tape guidance systems maintain close geometric tolerances to the prepreg cross section to control accurate tape placement, but the stiff tape does not buckle easily, so it may pass through an air gap between head components without difficulty. All critical components are highly modular to allow rapid change-out for scheduled maintenance. Our patented HGT is used to reduce the resin matrix viscosity at the nip point of the compaction roller and substrate. This heat energy does not serve to cure the resin system, only to reduce viscosity to allow consistent starts and high quality consolidation. The temperature is closely monitored and controlled to assure optimum consolidation.

This rapid automated process produces parts with low residual stresses (particularly important in very thick parts) and eliminates post-processing and the use of expensive consumables. The structures produced using this in-situ consolidation tape placement process are high quality, well consolidated structures which have low void content, an excellent finish, superior fiber concentricity, and minimal fiber buckling. The process also allows tape to be placed in any orientation from 0 degrees (axial reinforcement) to 90 degrees (hoop / circumferential reinforcement). This capability, unavailable in many other conventional methods of automated composite processing, allows stiffness and strength to be optimized for each application, thereby minimizing structural weight and cost.

In some cases, the automation of a thermoplastic preform may be the requirement. The Customer's previously qualified autoclave process, highly complex geometries, qualified tooling that is not well suited for fiber placement or the need for unconsolidated subcomponents might dictate that the in-situ consolidation process is not appropriate. We offer high speed thermoplastic preforming technology in single tape placement and multi-tape, individual tow control configurations. Hot gas heating is still employed, but a conformable roller is utilized and the process rate is typically increased to a level that full consolidation is not realized for a given heat energy input. The resulting preform is welded together and highly stable, ready for a traditional post process, such as autoclave consolidation.

Thermoplastic composites are replacing traditional metal and thermoset composite components. They are being used for secondary structure in aerospace, as well as in a growing number of applications in industries such as defense, fluid transfer, down-hole, automotive, and many others.

The unique chemical and mechanical properties of thermoplastic composites may include:

• High temperature performance appropriate for application to 480°F (250°C) / 30,000 psi (2,000 BAR)
• Outstanding chemical resistance
• Superior toughness and damage resistance
• Outstanding fatigue resistance
• Excellent vibration damping
• Reformable and recyclable
• Fusion as well as adhesive joining methods

Additional advantages of thermoplastics include:

• No refrigeration of material required- unlimited shelf life
• Eliminate bagging materials and labor
• Eliminate autoclave cost, space, and processing time
• Improved hot/ wet performance
• Improved solvent and corrosion resistance
• Repairable/ reprocessable
• Low residual stress- very thick section parts
• Simpler, longer lasting tooling (due to out-of-autoclave in-situ process)
• Reduced part count and assembly time through melt-bonding of stiffened structures

See Thermoset Processing

Visit our Photo Gallery and Video Library for customer examples.

Thermoset Processing

Automated Dynamics' unique automated thermoset processing offers many benefits which are reflected in part quality, process time, and competitive advantage. Process head solutions are provided for automated fiber placement (AFP) and automated tape laying (ATL) of unidirectional and fabric prepreg systems.

Typical aerospace, ATL grade, toughened epoxies are utilized with carbon and glass fiber reinforcements. The equipment is used to accurately place and simultaneously debulk the prepreg material onto the tool surface, through user-developed part programs, to provide high performance composite structures. The systems incorporated in our automated thermoset processes, including the elastomeric compaction roller, are so effective at achieving near net shapes that intermediate debulk steps are typically eliminated for even the thickest laminates. Consequently, fabrication time and manufacturing space are dramatically reduced, as compared with hand layup and other high touch labor intensive thermoset processing technologies.

 

The inherent drape and high tack of thermosetting resins at typical ambient conditions makes them challenging to handle in an automated system. Close attention must be paid to all areas of machine-to-prepreg contact and drape and tack must be reduced to mitigate handling and resin migration issues. The feed chamber of the head, where prepreg contact is highest, is enclosed and incorporates a cooling system and special approved contact surface coatings on all guide chutes and rollers, feed rollers, and pinch and clamp rollers. The cooled feed environment makes the prepreg stiff and "boardy", increasing feed reliability and reducing resin build-up. All tape guidance systems must maintain close geometric tolerances to the prepreg cross section to prevent buckling during the feed sequence. All critical components are highly modular to allow rapid change out for scheduled cleaning. A hot gas torch or IR lamp is used to increase prepreg tack at the nip point of the compaction roller and substrate. This heat energy does not serve to cure the resin system, only to reduce viscosity to allow consistent starts and high quality debulk. The temperature is closely monitored and controlled to prevent resin damage.

See Thermoplastic Processing.

View our Photo Gallery & Video Library for customer examples.