Methods and apparatus for automating the fiber laying process during the repair of composite structures made of fiber-reinforced plastic material based on the three-dimensional printing technique. Continuous fiber rovings (e.g., carbon fibers) impregnated with liquid epoxy can be directly printed onto the damaged surface of the composite structure (e.g., an aircraft component made of carbon fiber-reinforced plastic) without human manipulation in an autonomous manner.

Methods and apparatus for automating the fiber laying process during the repair of composite structures made of fiber-reinforced plastic material based on the three-dimensional printing technique. Continuous fiber rovings (e.g., carbon fibers) impregnated with liquid epoxy can be directly printed onto the damaged surface of the composite structure (e.g., an aircraft component made of carbon fiber-reinforced plastic) without human manipulation in an autonomous manner.

Provided herein is a method for repairing a composite material, a layup manufacturing process of a composite and a system for manufacturing a 3-dimensional composite part. The method, process and system all utilize a dielectric barrier discharge applicator to generate a plasma to cure an epoxy material to bond a patch to a composite material or to bond two or more layers of composite material together in a 3-dimensional shape to form a composite part.

Provided herein is a method for repairing a composite material, a layup manufacturing process of a composite and a system for manufacturing a 3-dimensional composite part. The method, process and system all utilize a dielectric barrier discharge applicator to generate a plasma to cure an epoxy material to bond a patch to a composite material or to bond two or more layers of composite material together in a 3-dimensional shape to form a composite part.

A robot taping system for applying a sticky tape onto of an object; the robot taping system comprising: a scanner to scan the object; a computer to generate a 3D model of the object from a scan of the object obtained by the scanner, the computer allowing a user to define a selected area and the computer generating a taping path for covering the selected area with the tape; a programmable robotic arm configured to move along a trajectory corresponding to the taping path; a taping tool attached to a free end of the robotic arm and comprising a tape holder rod to support a roll of the tape thereabout and from where the tape is dispensed; and a taping roller to contact a non-sticky side of the tape and to press the sticky side of a tape onto the selected area during movement of the robotic arm along the trajectory.

A robot taping system for applying a sticky tape onto of an object; the robot taping system comprising: a scanner to scan the object; a computer to generate a 3D model of the object from a scan of the object obtained by the scanner, the computer allowing a user to define a selected area and the computer generating a taping path for covering the selected area with the tape; a programmable robotic arm configured to move along a trajectory corresponding to the taping path; a taping tool attached to a free end of the robotic arm and comprising a tape holder rod to support a roll of the tape thereabout and from where the tape is dispensed; and a taping roller to contact a non-sticky side of the tape and to press the sticky side of a tape onto the selected area during movement of the robotic arm along the trajectory.

A microwave heating device includes a variable frequency microwave power supply, a waveguide launcher, and a fixture to contain a material to be heated, with the fixture located directly adjacent to the end of the launcher. All heating occurs in the near-field region. This condition may be insured by keeping the thickness of the fixture or workpiece under one wavelength (at all microwave frequencies being used). The launcher is preferably a horn or waveguide configured to apply the microwave power to a small area to perform spot curing or repair operations involving adhesives and composites. The spot curing may secure components in place for further handling, after which a thermal or oven treatment will cure the remaining adhesive to develop adequate strength for service.

Methods and apparatus for automating the fiber laying process during the repair of composite structures made of fiber-reinforced plastic material based on the three-dimensional printing technique. Continuous fiber rovings (e.g., carbon fibers) impregnated with liquid epoxy can be directly printed onto the damaged surface of the composite structure (e.g., an aircraft component made of carbon fiber-reinforced plastic) without human manipulation in an autonomous manner.

Methods and apparatus for automating the fiber laying process during the repair of composite structures made of fiber-reinforced plastic material based on the three-dimensional printing technique. Continuous fiber rovings (e.g., carbon fibers) impregnated with liquid epoxy can be directly printed onto the damaged surface of the composite structure (e.g., an aircraft component made of carbon fiber-reinforced plastic) without human manipulation in an autonomous manner.

A method is provided for working on a composite body. This method includes: disposing material within an aperture in the composite body, the material comprising fiber reinforcement and uncured resin, and the aperture extending into the composite body from a non-planar surface; forming a first chamber between the composite body and a first bag member, the material within the first chamber; disposing a support structure on the first bag member, the support structure overlapping the material; forming a second chamber between the first bag member and a second bag member, the support structure within the second chamber; drawing a vacuum of a first amount in the first chamber; and drawing a vacuum of a second amount in the second chamber.