Composites Automation LLC (CA) and our academic partner University of Delaware – Center for Composite Materials (UD-CCM) teamed to investigate and optimize the automated tape placement (ATP) processing of thin-ply composites. This effort included developing an understanding of the physical and mechanical characteristics of the incoming tape material and how the handling and machinery components affect these parameters. In addition, this effort initiated the development of a modeling foundation that captures the controllable machine parameters in the thin-ply tape placement. This was used to provide guidance for machine modifications to the equipment used in this investigation as well as for other existing or new processing equipment.
Test panels were also fabricated using the modified process conditions to demonstrate the improvements in mechanical properties compared to prior test panel results. A final demonstration component was fabricated to demonstrate complex part manufacturing with ply drops and layer -by layer orientation changes. Keys to successful transition of standard ply to thin-ply ATP processing, is the ability to fabricate uniform high fiber volume and fiber distribution composite parts at or below 1% void content.