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.

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