A system for manufacturing a composite part. The system comprises fiber placement devices, an overhead track system, and a scheduling controller. The fiber placement devices are configured to operate in a coordinated manner to place fibers at locations on a tool used for manufacturing the composite part. The overhead track system comprises a linear track running co-axial to the tool. The overhead track system is associated with the fiber placement devices and configured to move the fiber placement devices to the locations along a length of the tool. The scheduling controller is configured to coordinate operation of the fiber placement devices such that the fiber placement devices perform tasks simultaneously to place the fibers in a desired configuration on the tool.

A pressure bulkhead for a pressurized vehicle such as an aircraft employs a plurality of layers of composite fiber material having uni-directional fibers arranged in a single direction within the composite fiber material. The pressure bulkhead incorporates non-traditional radial and circumferential stiffening members into a composite laminate and aligns the radial stiffening members with the direction of dominant load paths. The radial and circumferential stiffening members are interlaid between full layers of the composite fiber material. Related methods of manufacturing the pressure bulkhead include using automated fiber placement equipment to form each layer of the pressure bulkhead and discretely orient the integral stiffeners and the uni-directional fibers in each layer.

There is provided a lay-up head for applying elongate fibre reinforcement material to an application surface. The lay-up head comprises a support head having a transverse axis, a dispensing mechanism carried by the support head for dispensing elongate fibre reinforcement material, and a roller for pressing elongate fibre composite material against the application surface. The roller is tiltable with respect to the support head such that the roller axis can be angled with respect to the transverse axis of support head. The lay-up head also comprises a holding mechanism operable to hold the roller in a central position in which the roller axis is parallel to the transverse axis of the support head.

There is disclosed a lay-up apparatus for laying up fibre reinforcement material, the lay-up apparatus comprising a lay-up tool defining a lay-up surface, a placement head having a flexible membrane which is conformable to the layup surface, and a membrane vacuum port extending through the membrane and configured to hold a ply against the membrane when suction is applied through the membrane vacuum port. The placement head is configured to cooperate with the lay-up tool so that when a ply is held against the membrane, an airtight chamber is formed between the membrane and the lay-up tool. The lay-up tool comprises a consolidation vacuum port configured to permit evacuation of the airtight chamber to cause the membrane and ply to move towards the lay-up surface.

A fiber composite laying method for producing a fiber composite scrim for forming a fiber composite component. The method includes supplying a reinforcement fiber band to a laying head, laying and compacting the supplied reinforcement fiber band on a laying surface at an average compaction pressure by a compaction roller, and detecting a local compaction pressure on the laid reinforcement fiber band by pressure sensors on the compaction roller.

A fiber composite laying device for producing a fiber composite scrim for forming a fiber composite component has a laying head which is designed or configured to continuously supply a reinforcement fiber band, a compaction roller which is designed or configured to receive the supplied reinforcement fiber band, lay the band on a laying surface and press the band onto the laying surface at an average compaction pressure, and pressure sensors which are arranged on the compaction roller and are designed or configured to detect a local compaction pressure on the laid reinforcement fiber band.

A fiber bundle cutting method in an automated fiber bundle placement apparatus includes: obtaining a placement length of a fiber bundle in an operating time of a movable blade from a start time point of a drive period to an end time point of a contact period, based on an operating time and a basic speed; setting, as a first time point, a time point determined as preceding the start time point by a predetermined preceding period; obtaining an additional speed to extra deliver at least a placement length during the preceding period; changing a feeding speed from an actual feeding speed to a corrected feeding speed obtained by adding the additional speed to the actual feeding speed at the first time point; and stopping rotary drive of a roller by a drive motor at the start time point.

An automated fiber placement (AFP) system includes a tool head with a compaction roller and a first variable heat source. The compaction roller is configured to receive at least one of a fiber and a plurality of fibers formed as a laydown tape, and is controlled to apply the laydown tape to a workpiece at a predetermined speed and direction. The first variable heat source is configured to apply a first amount of heat to the laydown tape. The first amount of heat applied is related to the predetermined speed. The AFP system further includes a second variable heat source configured to apply a second amount of heat to the workpiece. The second amount of heat applied is related to at least one of: a position on the workpiece, a thickness of the workpiece at that position, and a separation distance between the second variable heat source and the workpiece.

To provide a method of manufacturing a shaft-shape composite member in which a bent section is suitably treated. A plurality of thermosetting fiber-reinforced resin materials made of a UD material is supplied to a bending section of a mold in a state of being aligned in parallel to an axial direction of a cavity to form a UD material layer. Subsequently, after forming a tubular member having the UD material layer by the metal mold, by thermally curing the tubular member, the shaft-shape composite member having the bent section can be obtained. When manufacturing the shaft-shape composite member, a cross-section orthogonal to the axial direction of each of the fiber-reinforced resin materials has a circular shape.

A solution for fiber placement tow guides, known as “scoops,” to be cooled that allows for increased heating of outgoing tows while having cooling channels within the scoop to avoid melting, layup of thermoplastic materials will often see material temperatures of over 800° Fahrenheit, which means the heat shield will be heated to even higher temperatures that distorts existing scoops to a degree where they cause unwanted layup quality or may even melt certain scoops.