Systems, methods, and devices of the various embodiments may provide Automated Tape (or Tow) Placement (ATP) systems including machine-based parts that support prepreg tape laying processes to build composite parts. Various embodiments may be applied to materials that may be consolidated during fabrication and/or may be used to fabricate parts that may require post processing steps.

Shifting is a method for manipulating unidirectional non-crimp fabrics that allows for a curved fiber path along with compound surface geometry. The bases for shifting is understanding unidirectional (UD) non-crimp-fabrics (NCFs) as a semi-flexible prismatic linkage and planning manipulations such that the array of linkages can conform to the surface geometry and path plan within allowable manufacturing tolerances. This has applications in structural composite components such as the current trailing edge prefabricated unidirectional components for wind turbine blades, and for future wind turbine blade designs including a curve-linear spar cap.

A composite prepreg laminate such as a hat type-stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

An automated fiber bundle placement apparatus including a placing head having a pressing device, and a multi-jointed robot. The pressing device includes a pressing part, a pressing mechanism having a drive device, and a drive control device. The drive control device includes a drive command unit configured to output a drive command corresponding to a contact width of a placement die with the pressing part, the contact width being a length in the width direction of a part of the placement die facing in parallel to a contact range of the pressing part during pressing against the placement die, and is configured to control drive of the drive device to apply a pressing force corresponding to the drive command to the pressing part.

The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of printheads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of printheads is moveable along the first axis, the second axis, or both. At least one of the printheads of the plurality of printheads is moveable independently of one another along a third axis.

An applicator head (1) for the application of a composite tape (2) fed from a supply reel (3) to a surface for the deposition thereof; the tape (2) being formed by a layer of composite material (2.1) disposed on a supporting layer (2.2). The applicator head (1) comprises a cutting means (30), compaction means (40) and/or collection means (50). The cutting means (30) is displaced in a first direction of displacement of a first blade (31) at an angle with regard to a second direction of displacement of a second blade (32). The compaction means (40) has an application separator (41) configured to separate the layer of composite material (2.1) from the supporting layer (2.2) at a certain height from the surface for the deposition thereof. And the collection means (50) has a collection separator (52) configured to separate the unused layer of composite material (2.1) and to collect it in a collection container (53).

A method of manufacturing a fibre-composite article is described, wherein a layer of fibre material is applied from a layup head to a mould along a layup path. The angle at which the fibre material is dispensed from the layup head is rotated relative to the angle of orientation of the layup path, to minimise the effects of gravity on the alignment of the fibre layer in the mould. The fibre-composite article is preferably a section of a blade for a wind turbine.

A method of manufacturing a fibre-composite article is described, wherein a layer of fibre material is applied from a layup head to a mould along a layup path. The angle at which the fibre material is dispensed from the layup head is rotated relative to the angle of orientation of the layup path, to minimise the effects of gravity on the alignment of the fibre layer in the mould. The fibre-composite article is preferably a section of a blade for a wind turbine.

Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

A method for manufacturing a wind turbine blade includes the use of an apparatus having an engagement part. The engagement part has: a support element having a first support edge and a second support edge, a belt extending around the support element and forming a primary engagement edge of the engagement part along the first support edge of the support element. The method includes: providing one or more pre-shaped elements, including a first pre-shaped element, in a first element position, positioning the engagement part in a first position, moving the support element in a first direction with a first velocity to extend underneath the first pre-shaped element, and at the same time moving the belt relative to the support element around the first support edge in a primary direction from below the first support edge to above the first support edge with a primary velocity.