Automated method and system for trimming multilayer structures

Abstract

The present invention is entitled "Automated Method and System for Trimming a Multi-Ply Structure." An automated method for trimming a multi-ply structure having at least a first ply and a second ply is provided, wherein the method comprises applying the first ply to a platen, positioning a cutting board over a protected portion of the first ply, applying the second ply to the platen such that the cutting board is located between the protected portion of the first ply and an overlying portion of the second ply, and cutting the overlying portion of the second ply.

Description

Technical Field

[0001] The present disclosure relates generally to composite structures and, more particularly, to apparatus and methods for forming composite materials. Still more particularly, the present application relates to apparatus and methods related to forming and trimming multilayer sheet structures. Background Art

[0002] Composite structures are widely used as high-strength, low-weight materials to replace metals, such as in aerospace applications. A composite structure (e.g., a composite ply deck) is formed from one or more composite layers (also known as plies or sheets). Each composite layer includes a reinforcement material and a matrix material. The reinforcement material may include fibers. The fibers may be oriented in a single direction (e.g., unidirectional) or in two directions (e.g., bidirectional). The matrix material may include a resin.

[0003] The fiber bundles can be laid up in layers to form a reinforcement layup, such as a preform. Resin is injected into the spaces defined between the fiber bundles of the preform to form an integral preform. When the fiber bundles have been pre-impregnated with resin, the preform can be referred to as a wet preform (or prepreg), or when no resin is present, as a dry preform. The integral preform can be partially cured or fully cured to form a composite structure. An example of a composite structure is a carbon fiber reinforced polymer.

[0004] It is desirable to trim or cut the laid-up plies to form a preform. It is also desirable to trim or cut the laid-up plies to form a preform using an automated process and / or automated system. Existing automated processes and / or automated systems only address the problem of trimming a single ply or the entire ply pallet thickness at a time. Currently, there are no solutions for differentially trimming components of a ply structure simultaneously.

[0005] Consequently, those skilled in the art continue to conduct research and development work in the field of automated methods and systems for trimming multilayer structures. Summary of the Invention

[0006] An example of a disclosed automated method for trimming a multi-ply structure having at least a first ply and a second ply includes applying the first ply over a platen, positioning a cutting board over a protected portion of the first ply, applying the second ply over the platen such that the cutting board is between the protected portion of the first ply and an overlying portion of the second ply, and cutting the overlying portion of the second ply.

[0007] An example of a disclosed automated method for trimming a multilayer structure having at least a first ply having a first composite material and a second ply having a second composite material includes positioning a film above a platen, positioning a cutting plate above a protected portion of the film, applying the first ply above the platen with a laminator so that the cutting plate is positioned between the protected portion of the film and an overlying portion of the first ply, cutting the overlying portion of the first ply, positioning the cutting plate above the protected portion of the first ply, applying the second ply above the platen with a laminator so that the cutting plate is positioned between the protected portion of the first ply and the overlying portion of the second ply, and cutting the overlying portion of the second ply.

[0008] An example of a disclosed automated multi-ply structure finishing system includes a platen, a laminator movable relative to the platen to apply at least a first ply and a second ply above the platen, a cutting plate movable relative to the platen and positionable between the first ply and the second ply, and a cutting tool movable relative to the platen to cut the second ply.

[0009] Other examples of the disclosed apparatus and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is an elevation view of a first example of an automated multi-layer sheet structure trimming system in a first configuration.

[0011] Figure 2 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a second configuration.

[0012] Figure 3 is an elevational view of the first example of the automated multi-layer sheet structure trimming system in a third configuration and with a further optional modification showing slots.

[0013] Figure 4 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a fourth configuration.

[0014] Figure 5 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a fifth configuration.

[0015] Figure 6 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a sixth configuration.

[0016] Figure 7 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a seventh configuration.

[0017] Figure 8is an elevation view of the first example of an automated multi-layer sheet structure trimming system in an eighth configuration.

[0018] Figure 9 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a ninth configuration.

[0019] Figure 10 is an elevation view of the first example of an automated multi-layer sheet structure trimming system in a tenth configuration.

[0020] Figure 11A is a block diagram of an example of a cutting tool including an ultrasonic knife.

[0021] Figure 11B is a block diagram of an example of a cutting tool including a mechanical knife.

[0022] Figure 11C is a block diagram of an example of a cutting tool including a wheel cutter.

[0023] Figure 12A is a top view of a first example of a multilayer structure before trimming.

[0024] Figure 12B is a top view of the first example of a multilayer structure after trimming.

[0025] Figure 13 is a top view of a second example of an automated multi-layer sheet structure trimming system in a first configuration.

[0026] Figure 14 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a second configuration.

[0027] Figure 15 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a third configuration.

[0028] Figure 16 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a fourth configuration.

[0029] Figure 17 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a fifth configuration.

[0030] Figure 18A is a front view of a deck with a set of cutting plates in a first configuration.

[0031] Figure 18B is a front view of the deck with a set of cutting plates in a second configuration.

[0032] Figure 18Cis a front view of the deck with a set of cutting plates in a third configuration.

[0033] Figure 19 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a sixth configuration.

[0034] Figure 20 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a seventh configuration.

[0035] Figure 21 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in an eighth configuration.

[0036] Figure 22 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a ninth configuration.

[0037] Figure 23 is an elevation view of a second example of an automated multi-layer sheet structure trimming system in a tenth configuration.

[0038] Figure 24 is a block diagram of the first method.

[0039] Figure 25 is a block diagram of the second method. DETAILED DESCRIPTION

[0040] The following detailed description refers to the accompanying drawings, which illustrate specific non-limiting examples of the present disclosure. Other examples with different structures and operations do not depart from the scope of the present disclosure. The same reference numerals in different figures may refer to the same elements or parts.

[0041] Figure 1-10 A first non-limiting example of an automated multi-ply sheet structure finishing system (15) is illustrated. The automated multi-ply sheet structure finishing system (15) includes a platen (140); a laminator (170) that is movable or fixed relative to the platen (140) to lay at least a first ply (120) (see Figure 3 ) and the second layer (130) (see Figure 8 ) is applied to the top of the platen (140); a cutting plate (152) which is movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130) (see Figure 8 ) between; and cutting tool (160) (see Figure 4 ), which is movable about the platen (140) to cut the second ply (130).

[0042] In some instances, the platen (140) comprises any form or geometry selected through good engineering judgment. In some instances, the platen (140) is planar or substantially planar. In other acceptable instances, the platen (140) is not planar. In some acceptable instances, the platen (140) is contoured. In some instances, the platen (140) is movable relative to one or more other components described for the methods and systems described herein. In some instances, the platen (140) is configured to be movable by some automated actuator. As further described below, in some instances, the platen (140) is movable relative to one or more workstations (10).

[0043] In some examples, the first ply (120) is applied over the platen (140) such that the first ply (120) is in direct contact with the platen (140). An acceptable alternative is to apply the first ply (120) over the platen (140) such that the first ply (120) is not in direct contact with the platen (140), but is in indirect contact with the platen (140) via a film (142) or other intermediate material. The film (142) will be further described below. In some examples, the second ply (130) is applied over the platen (140) such that at least a portion of the second ply (130) is in direct contact with the platen (140). An acceptable alternative is to apply the second layer (130) over the platen (140) such that at least a portion of the second layer (130) is not in direct contact with the platen (140), but is in indirect contact with the platen (140) through the film (142) or the first layer (120) or other intermediate material.

[0044] Reference Figure 12A and 12B In some non-limiting examples, the first ply (120) and the second ply (130) are staggered or positioned so that the second ply (130) does not completely cover the first ply (120) at all points. Figure 12A and 12B In those shown, the first layer (120) at least partially covers the film (142) on the table (140), and the second layer (130) partially covers the first layer (120) and partially covers the table (140) and / or the film (142) on the table (140).

[0045] The laminator (170) includes any classification of laminators (170) selected through good engineering judgment. Some optional examples include multiple laminators (170). The laminator (170) is movable or fixed with respect to one or more other components described for the methods and systems described herein. In some examples, the laminator (170) is configured to be movable by some automated actuators (162). In some examples, the laminator (170) is movable with respect to the platen (140) and the cutting board (152). In some optional examples, the laminator (170) is fixed with respect to the platen (140) and the cutting board (152). In some optional instances, there are multiple laminators (170), wherein the 0 degree laminator (170) is fixed and the platen (140) is movable relative to the 0 degree laminator (170) to pay out material for the first layer (120) or the second layer (130); and a movable 45 degree laminator (170) or a movable 90 degree laminator (170), or both a movable 45 degree laminator (170) and a movable 90 degree laminator (170).

[0046] The cutting plate (152) is selectively movable and positionable to prevent cutting of an underlying component or material, such as, for example, the platen (140), the film (142), the first ply (120), or the second ply (130). In some non-limiting examples, the system includes one, two, three, or more cutting plates (152). The cutting plate (152) is configured to be movable relative to the platen (140) about a rotation axis (156). In other non-limiting examples, the cutting plate (152) is configured to be movable relative to the platen (140) by translation or by some combination of translation and rotation. In some non-limiting examples, such as Figure 10 As shown in FIG. 1 , the rotation axis (156) is perpendicular to at least one imaginary vector (12) that is normal to the cutting plate (152). In some non-limiting examples, the rotation axis (156) is parallel to at least one imaginary vector that is normal to the cutting plate (152). In some examples, the rotation axis (156) is spatially fixed relative to the cutting plate (152), but this is not always the case in every example.

[0047] Continue to refer Figure 1-10In some instances, the cutting tool (160) is movable relative to the platen (140) and is capable of cutting the first ply (120) or the second ply (130), or the second ply (130) and the first ply (120), or some other group of plies. In some instances, the cutting tool (160) is not capable of cutting the cutting plate (152). In some instances, the cutting tool (160) is only capable of cutting the cutting plate (152) very lightly or slowly, such that the cutting plate (152) is only lightly cut by any given cutting operation and will last for multiple cutting operations. In some instances, the cutting plate (152) will last for at least two cutting operations. In some instances, the cutting tool (160) is not capable of cutting the second cutting plate (182). In some instances, the cutting tool (160) is only capable of cutting the second cutting plate (182) very lightly or slowly, such that the second cutting plate (182) is only lightly cut by any given cutting operation and will last for multiple cutting operations. In some instances, the second cutting plate (182) will last for at least two cutting operations. In some instances, during a cutting operation, the cutting tool (160) will be in contact with the cutting plate and cut all the way through the composite material in a single pass. Figures 11A-11C As shown in FIG, in some examples, the cutting tool (160) will include one or more of an ultrasonic blade (163), a mechanical blade (165), and a gear cutter (167). In other non-limiting examples, the cutting tool (160) is some other type of tool that does not include any of the ultrasonic blade (163), the mechanical blade (165), or the gear cutter (167). In some examples, the cutting tool (160) is operated to cut a portion of the material above the cutting plate (152), each of these latter portions being referred to as an overlying portion, while leaving the protected portion (20) below the cutting plate (152) uncut.

[0048] Continue to refer Figure 1-10 In some examples, the system (15) optionally includes a film (142) positioned above the platen (140). In such examples, the platen (140) supports the film (142) positioned above the platen (140). In other non-limiting examples, the system (15) does not include the film (142) positioned above the platen (140) or the platen (140) does not support the film (142) positioned above the platen (140). In some examples, the film (142) is in direct contact with the platen (140). In some examples, the film (142) is in indirect contact with the platen (140). In some examples, the film (142) is a release paper or some other material suitable for facilitating removal of the first ply (120) or another ply or material from the platen (140).

[0049] Continue to refer Figure 1-10In some examples, the system (15) further comprises a waste bin (16) (see Figure 5 ) is positioned to receive waste generated by the first ply (120) and / or the second ply (130). In some examples, the system (15) does not include a waste bin (16), includes one waste bin (16), two waste bins (16), or multiple waste bins (16). The waste bin (16) is adapted and / or positioned to receive discarded first waste (124) from the first ply (120), receive discarded second waste (134) generated from the second ply (130), receive discarded waste from another ply, or a combination thereof.

[0050] Continue to refer Figure 1-10 In some instances, the system (15) further includes one or more automated actuators. In some instances, the system (15) includes an automated actuator (162) operably associated with the platen (140) and adapted to move the platen (140); an automated actuator (162) operably associated with the laminator (170) and adapted to move the laminator (170); an automated actuator (162A) operably associated with the cutting board (152) and adapted to move the cutting board (152); or some combination thereof. In some instances, the system (15) includes an automated actuator (162B) operably associated with the cutting tool (160) such that the automated actuator (162B) is adapted to move the cutting tool (160) to perform a cutting operation. In some aspects, the automated actuator (162) is electromagnetic, pneumatic, hydraulic, or otherwise selected with good engineering judgment.

[0051] Figures 11A-11C Various non-limiting examples of cutting tools are illustrated.

[0052] Figures 12A-12B Illustrations of different ply arrangements and how to trim them.

[0053] Figure 13-23 A second non-limiting example of an automated multi-ply sheet structure finishing system (15) is illustrated. The automated multi-ply sheet structure finishing system (15) includes a platen (140); a laminator (170) that is movable or fixed relative to the platen (140) to lay at least a first ply (120) (see Figure 15 ) and the second layer (130) (see Figure 8 ) is applied to the top of the platen (140); a cutting plate (152) which is movable relative to the platen (140) and positionable between the first layer (120) and the second layer (130) (see Figure 16); a second cutting plate (182) which is movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130) (see Figure 16 ); and a cutting tool (160) and a second cutting tool (169), each of which is movable with respect to the platen (140) to cut the second ply (130).

[0054] In some aspects of the second non-limiting example, the platen (140) comprises any form or geometry selected by good engineering judgment. In some examples, the platen (140) is planar or substantially planar. In other acceptable examples, the platen (140) is not planar. In some acceptable examples, the platen (140) is contoured. In some examples, the platen (140) is movable relative to one or more other components described for the methods and systems described herein. In some examples, the platen (140) is configured to be movable by some automated actuators (162). As further described below, in some examples, the platen (140) is movable relative to one or more workstations (10).

[0055] In some aspects of the second non-limiting example, the first ply (120) is applied to the platen (140) such that the first ply (120) is in direct contact with the platen (140). An acceptable alternative is to apply the first ply (120) to the platen (140) such that the first ply (120) is not in direct contact with the platen (140), but is in indirect contact with the platen (140) through a film (142) or other intermediate material. The film (142) will be further described below. In some examples, the second ply (130) is applied to the platen (140) such that at least a portion of the second ply (130) is in direct contact with the platen (140). An acceptable alternative is to apply the second layer (130) over the platen (140) such that at least a portion of the second layer (130) is not in direct contact with the platen (140), but is in indirect contact with the platen (140) through the film (142) or the first layer (120) or other intermediate material.

[0056] In some aspects of the second non-limiting example, the laminator (170) includes any classification of laminators (170) selected through good engineering judgment. Some optional examples include multiple laminators (170). The laminator (170) is movable or fixed with respect to one or more other components described for the methods and systems described herein. In some examples, the laminator (170) is configured to be movable by some automated actuators (162). In some examples, the laminator (170) is movable with respect to the platen (140), the cutting board (152), and the second cutting board (182). In some optional examples, the laminator (170) is fixed with respect to the platen (140), the cutting board (152), and the second cutting board (182). In some optional instances, there are multiple laminators (170), wherein the 0 degree laminator (170) is fixed and the platen (140) is movable relative to the 0 degree laminator (170) to lay material for the first layer (120) or the second layer (130); and a movable 45 degree laminator (170) or a movable 90 degree laminator (170), or both a movable 45 degree laminator (170) and a movable 90 degree laminator (170).

[0057] In some aspects of the second non-limiting example, the cutting plate (152) is selectively movable and positionable to prevent cutting of an underlying component or material, such as, for example, the platen (140), the film (142), the first ply (120), or the second ply (130). The cutting plate (152) is configured to be movable relative to the platen (140) about a rotational axis (156) and movable relative to the platen (140) by translation. Figures 18A-18C As shown in FIG. 1 , the rotation axis (156) is perpendicular to at least one imaginary vector (12) that is normal to the cutting plate (152). In some non-limiting examples, the rotation axis (156) is parallel to at least one imaginary vector that is normal to the cutting plate (152). In some examples, the rotation axis (156) is spatially fixed relative to the cutting plate (152), but this is not always the case in every example.

[0058] In some instances of the second non-limiting example, the second cutting plate (182) is selectively movable and positionable to prevent cutting of an underlying component or material, such as, for example, the platen (140), the film (142), the first ply (120), or the second ply (130). The second cutting plate (182) is configured to be movable relative to the platen (140) about a second axis of rotation (186) and movable relative to the platen (140) by translation. Figures 18A-18CAs shown in FIG. 1 , the second rotational axis (186) is perpendicular to at least one imaginary vector (12) that is orthogonal to the second cutting plate (182). In some non-limiting examples, the second rotational axis (186) is parallel to at least one imaginary vector that is orthogonal to the second cutting plate (182). In some examples, the second rotational axis (186) is spatially fixed relative to the second cutting plate (182), but this is not always the case in every example.

[0059] Continue to refer Figure 13-23 In some examples, the cutting tool (160) and the second cutting tool (169) are each movable relative to the platen (140) and are each capable of cutting the first ply (120), or the second ply (130), or the second ply (130) and the first ply (120), or some other group of plies. In some examples, the cutting tool (160) is unable to cut the cutting plate (152). In some examples, the cutting tool (160) and the second cutting tool (169) are each capable of cutting the cutting plate (152) or the second cutting plate (182) only very lightly or slowly, such that the cutting plate (152) or the second cutting plate (182) is only lightly cut by any given cutting operation and will last for multiple cutting operations. In some examples, the cutting plate (152) and the second cutting plate (182) will each last for at least two cutting operations. In some examples, during the cutting operation, the cutting tool (160) will be in contact with the cutting plate and will cut all the way through the composite material in a single pass. In some examples, during the cutting operation, the second cutting tool (169) will contact the second cutting plate (182) and cut all the way through the composite material in a single pass. In some examples, the cutting tool (160) is operated to cut a portion of the material above the cutting plate (152), each of these latter portions being referred to as an overlying portion, while leaving the protected portion (20) below the cutting plate (152) uncut. In some examples, the second cutting tool (169) is operated to cut a portion of the material above the second cutting plate (182), each of these latter portions being referred to as an overlying portion, while leaving the protected portion (20) below the second cutting plate (182) uncut.

[0060] Continue to refer Figure 13-23 , and especially Figure 14 and 15In some examples, the system (15) optionally includes a film (142) positioned above the platen (140). In such examples, the platen (140) supports the film (142) positioned above the platen (140). In other non-limiting examples, the system (15) does not include the film (142) positioned above the platen (140) or the platen (140) does not support the film (142) positioned above the platen (140). In some examples, the film (142) is in direct contact with the platen (140). In some examples, the film (142) is in indirect contact with the platen (140). In some examples, the film (142) is a release paper or some other material suitable for facilitating removal of the first ply (120) or another ply or material from the platen (140).

[0061] Continue to refer Figure 13-23 , and especially Figure 22 In some examples, the system (15) further includes a waste bin (16) positioned to receive waste generated by the first ply (120) and / or the second ply (130). In some examples, the system (15) does not include a waste bin (16), includes one waste bin (16), two waste bins (16), or multiple waste bins (16). The waste bin (16) is adapted and / or positioned to receive discarded first waste (124) from the first ply (120), receive discarded second waste (134) generated from the second ply (130), receive discarded waste from another ply, or a combination thereof.

[0062] Continue to refer Figure 13-23In some instances, the system (15) further includes one or more automated actuators. In some instances, the system (15) includes an automated actuator (162) operably associated with the platen (140) and adapted to move the platen (140); an automated actuator (162) operably associated with the laminator (170) and adapted to move the laminator (170); an automated actuator (162A) operably associated with the cutting board (152) and adapted to move the cutting board (152); an automated actuator (162A) operably associated with the second cutting board (182) and adapted to move the second cutting board (182); or some combination thereof. In some instances, the system (15) includes an automated actuator (162B) operably associated with the cutting tool (160), such that the automated actuator (162B) is adapted to move the cutting tool (160) to perform a cutting operation. In some examples, the system (15) includes an automated actuator (162B) operably associated with the second cutting tool (169), such that the automated actuator (162B) is adapted to move the second cutting tool (169) to perform a cutting operation. In some examples, the automated actuator (162B) includes a trimming frame (144) and a trimming head (145). In certain aspects, the automated actuator (162) is electromagnetic, pneumatic, hydraulic, or other means selected through good engineering judgment.

[0063] exist Figure 13-23 In a second non-limiting example shown in , the system (15) further includes a second cutting plate (182) that is movable relative to the platen and positionable between the first ply (120) and the second ply (130). For example, Figure 13-23 A second example of an automated multi-layer sheet structure trimming system (15) is illustrated, comprising a cutting plate (152) and a second cutting plate (182). Figure 13-23As shown in , in some examples, the system (15) further includes a second cutting plate (182) that is movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130). The second cutting plate (182) is movable relative to the platen (140) about a rotational axis that is different from the rotational axis (156). In some non-limiting examples, the second cutting plate (182) is movable relative to the platen (140) by translation or by some combination of translation and rotation. In some non-limiting examples, the rotational axis of the second cutting plate (182) is perpendicular to at least one imaginary vector (12) that is orthogonal to the second cutting plate (182). In some non-limiting examples, the rotational axis of the second cutting plate (182) is parallel to at least one imaginary vector that is orthogonal to the second cutting plate (182). In some examples, the axis of rotation of the second cutting plate (182) is spatially fixed relative to the second cutting plate (182), but this is not always the case in every example. The portion of the underlying component or material protected by the cutting plate (152) or the second cutting plate (182) or another cutting plate is referred to herein as the protected portion (20).

[0064] Continue to refer Figure 13-23 And specific reference Figure 18A -C, in a second non-limiting example, the cutting plate (152) is adapted to rotate about a rotation axis (156) and to translate vertically or horizontally about the rotation axis (156) via a sliding slot (158). These adaptations allow the cutting plate (152) to move from a first vertical orientation (152A) to a second vertical position (152B) by translating upward and to move from the second vertical position (152B) to a horizontal orientation (152C) by rotating about the rotation axis (156). Figure 22 , if it is desired to dump the first waste material (124) from the cutting deck (152) into the waste bin (16). Similarly, these same adaptations allow the cutting deck (152) to move from the horizontal orientation (152C) to the second vertical position (152B) by rotating about the rotation axis (156) about the platen (140), and to move from the second vertical position (152B) to the first vertical orientation (152A) by translating downward.

[0065] Continue to refer Figure 13-23 And specific reference Figure 18A-C, in a second non-limiting example, the second cutting plate (182) is adapted to rotate about a second rotational axis (186) and to translate vertically or horizontally about the second rotational axis (186) via the sliding slot (158). These adaptations allow the second cutting plate (182) to move from a first vertical orientation (182A) to a second vertical position (182B) by translating upward, and to move from the second vertical position (182B) to a horizontal orientation (182C) by rotating about the second rotational axis (186). Figure 22 , if it is desired to dump the second waste material (134) from the second cutting deck (182) into the waste bin (16), the subsequent rotation can continue. Similarly, these same adaptations allow the second cutting deck (182) to move from the horizontal orientation (182C) to the second vertical position (182B) by rotating about the second rotation axis (186), and to move from the second vertical position (182B) to the first vertical orientation (182A) by translating downward.

[0066] Now refer to Figure 13-23 In some non-limiting example systems (15), the system further comprises a second cutting tool (169) having similar or identical characteristics and adaptability to the cutting tool (160). Figure 13-23 As shown in FIG, in some non-limiting examples, the cutting tool (160) or the second cutting tool (169) or both can be operably engaged with the trimming head (145), and each trimming head (145) can be moved over a desired cutting area by the trimming frame (144). Figure 13 As shown in FIG. 1 , the trimming gantry ( 144 ) may be an automated gantry or a Cartesian robot, but in other equally acceptable examples, the trimming gantry ( 144 ) is another automated actuator or robot.

[0067] refer to Figure 1-10and 24, further providing a first automated method (1000) for trimming a multi-ply structure (110) comprising at least a first ply (120) and a second ply (130). The first automated method (1000) optionally includes, at block 1100, moving a platen (140) into a workstation (10). The first automated method (1000) optionally includes, at block 1200, applying the first ply (120) above the platen (140). The first automated method (1000) optionally further includes, at block 1300, positioning a cutting plate (152) above a protected portion (20) of a film (142). The first automated method (1000) optionally further includes, at block 1400, cutting an overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply. The first automated method (1000) optionally further includes, at block 1500, discarding first scrap (124) from the first ply. The first automated method (1000) further includes, at block 1600, positioning a cutting plate (152) over the protected portion (20) of the first ply (120). The first automated method (1000) further includes, at block 1700, applying a second ply (130) over the platen (140) such that the cutting plate (152) is positioned between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130). The first automated method (1000) further includes, at block 1800, cutting the overlying portion (40) of the second ply (130). The first automated method (1000) optionally further includes, at block 1900, sliding the swing arm (154) about the rotation axis (156) using the slot (158). The first automated method (1000) may optionally further include discarding second waste material (134) from the second ply at block 1950. The first automated method (1000) may optionally further include positioning a second cutting plate (182) above the second protected portion (24) of the first ply (120) such that the second cutting plate (182) is between the second protected portion (24) of the first ply (120) and the second overlying portion (44) of the second ply (130) at block 1960. The first automated method (1000) may optionally further include cutting the second overlying portion (44) of the second ply (130) at block 1970.

[0068] Continue to refer Figure 1-10 In some instances, the first automated method further comprises positioning the film (142) above the platen (140) prior to applying the first ply (120). For example, Figure 1 Illustrated is a membrane (142) positioned above a platen (140).

[0069] Some non-limiting forms of the following first automated method further include positioning a cutting plate (152) over the protected portion (20) of the film (142) before applying the first ply (120). For example, Figure 2 Illustrated is the positioning of a cutting plate (152) over the protected portion (20) of the film (142) prior to application of the first ply (120).

[0070] In some non-limiting forms of the following first automated method, applying the first ply (120) is performed such that the cutting plate (152) is located between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120). For example, Figure 3 The first ply (120) is illustrated as being applied such that the cutting plate (152) is positioned between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120).

[0071] In some non-limiting forms of the following first automated method, cutting the overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply is performed after the first ply (120) is applied over the platen (140). In some examples, this latter cutting is performed before positioning the cutting plate (152) over the protected portion (20) of the first ply (120). For example, Figure 4 Illustrated is cutting of an overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply after the first ply (120) is applied over a platen (140) and before a cutting plate (152) is positioned over the protected portion (20) of the first ply (120).

[0072] In some non-limiting forms of the following first automated method, discarding the first waste material (124) from the first ply (120) is performed after cutting the overlying portion (40) of the first ply (120). In some examples, the following discarding is performed before positioning the cutting plate (152) over the protected portion (20) of the first ply (120). For example, Figure 5 Illustrated is discarding a first scrap (124) from the first ply (120) after cutting the overlying portion (40) of the first ply (120) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120).

[0073] In some non-limiting forms of the following first automated method, positioning the cutting plate (152) over the protected portion (20) of the first ply (120) is performed by rotating the cutting plate 152 about a rotation axis 156. For example, Figure 6-7Positioning the cutting plate (152) over the protected portion (20) of the first ply (120) is illustrated as being performed by rotating the cutting plate 152 about an axis of rotation 156.

[0074] In some non-limiting forms of the following first automated method, applying the second ply (130) over the platen (140) is performed such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130). For example, Figure 7-8 Illustrated is the application of the second ply (130) over the platen (140) being performed such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130).

[0075] In some non-limiting forms of the following first automated method, cutting the overlying portion (40) of the second ply (130) is performed. For example, Figure 9 The overlying portion (40) of the second ply (130) is illustrated cut.

[0076] In some non-limiting forms of the latter first automated method, discarding second waste material from the second ply (134) is performed. For example, Figure 10 Discarding of second waste (134) from the second ply is illustrated.

[0077] Some, but not all, non-limiting forms of the following automated method further include, after applying the first ply (120) over the platen (140) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120), cutting the overlying portion (40) of the first ply (120) to produce a first scrap material (124) from the first ply. Some, but not all, non-limiting forms of the following automated method further include, after cutting the overlying portion (40) of the first ply (120) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120), discarding the first scrap material (124) from the first ply. In some non-limiting forms of the following automated methods, cutting the overlying portion (40) of the first ply (120) includes moving a cutting tool (160) relative to the first ply (120), and cutting the overlying portion (40) of the second ply (130) includes moving the cutting tool (160) relative to the second ply (130). As described above, in some examples, the cutting tool (160) is operably engaged with the automated actuator (162B) and / or includes at least one of an ultrasonic blade (163), a mechanical blade (165), and a gear cutter (167).

[0078] Continue to refer Figure 1-10In some non-limiting forms of the first automated method, cutting the overlying portion (40) of the second ply (130) produces second waste material (134) from the second ply. Some non-limiting forms of the latter automated method further include discarding the second waste material (134) from the second ply.

[0079] Continue to refer Figure 1-10 In some non-limiting forms of the first automated method, applying the first ply (120) over the platen (140) includes using a laminator (170) that is movable with respect to the platen (140).

[0080] Continue to refer Figure 1-10 , and refer to Figure 12A and 12B In some non-limiting forms of the first automated method, the first ply (120) includes a first composite material (125). In some non-limiting forms of the latter automated method, the first composite material (125) includes a first polymer matrix (126) and a first reinforcing fiber (128) (see Figure 5 In some non-limiting forms of the following automated method, the first polymer matrix (126) comprises a thermosetting resin (127), or the first reinforcing fibers (128) comprise carbon fibers (129), or both (see Figure 5 In some non-limiting examples, the first polymer matrix (126) includes a thermoplastic resin, a thermosetting resin (127), or some combination thereof. In some non-limiting examples, the thermosetting resin (127) includes an epoxy resin. In some non-limiting examples, the first reinforcing fibers (128) include glass fibers, carbon fibers, steel fibers, aramid, or some combination thereof.

[0081] Continue to refer Figure 1-10 , and refer to Figure 12A and 12BIn some non-limiting forms of the first automated method, the first ply (120) comprises a first composite material (125), and the second ply (130) comprises a second composite material (135). In some non-limiting forms of the latter automated method, the second composite material (135) comprises a second polymer matrix (136) and second reinforcing fibers (138). In some non-limiting forms of the latter automated method, the second polymer matrix (136) comprises a thermosetting resin (127), or the second reinforcing fibers (138) comprise carbon fibers (129), or both. In some non-limiting forms, the second composite material (135) is substantially identical to the first composite material (125). Composite materials are considered substantially identical for these purposes if the differences between the composite materials are small enough to allow the materials to be interchanged for these purposes. In some non-limiting examples, the second polymer matrix (136) comprises a thermoplastic resin, a thermosetting resin (127), or some combination thereof. In some non-limiting examples, the second reinforcing fibers (138) include glass fibers, carbon fibers, steel fibers, aramid, or some combination thereof.

[0082] Continue to refer Figure 1-10 In some non-limiting forms of the first automated method, positioning the cutting plate (152) above the protected portion (20) of the first ply (120) includes positioning the cutting plate (152) in direct contact with the protected portion (20) of the first ply (120). In other non-limiting examples, positioning the cutting plate (152) above the protected portion (20) of the first ply (120) includes positioning the cutting plate (152) in indirect contact with the protected portion (20) of the first ply (120), such as in direct contact with an intermediate material between the cutting plate (152) and the protected portion (20) of the first ply (120), or offset from the protected portion (20) of the first ply (120) by a gap.

[0083] Continue to refer Figure 1-10 In some non-limiting forms of the first automated method, coupling the cutting plate (152) to the swing arm (154), and positioning the cutting plate (152) over the protected portion (20) of the first ply (120) includes rotating the swing arm (154) about a rotation axis (156). In some non-limiting forms of the latter automated method, rotating the swing arm (154) is accomplished by an automated actuator (162A), or the method further includes sliding the swing arm (154) about the rotation axis (156) using a slot (158), or both.

[0084] Continue to refer Figure 1-10In some non-limiting forms of the first automated method, applying the second ply (130) over the platen (140) includes using a laminator (170) that is movable or fixed with respect to the platen (140).

[0085] Continue to refer Figure 1-10 Some non-limiting forms of the first automated method further include moving the platen (140) into or out of the workstation (10), or from one workstation (10) to another workstation (10).

[0086] Further references Figure 14-23 In some non-limiting forms of the second automated method, the second cutting plate (182) is positioned above the second protected portion (24) of the first ply (120) such that the second cutting plate (182) is between the second protected portion (24) of the first ply (120) and the second overlying portion (44) of the second ply (130); and cutting the second overlying portion (44) of the second ply (130). In some non-limiting forms of the latter automated method, cutting the second overlying portion (44) of the second ply (130) includes moving the second cutting tool (169) relative to the second ply (130).

[0087] Further references Figure 13 In some non-limiting forms of the second automated method, the automated actuator (162A) is operably associated with the second cutting deck (182) and adapted to move the second cutting deck (182).

[0088] In some non-limiting forms of the second automated method, the system (15) includes an automated actuator (162B) operably associated with the second cutting tool (169), such that the automated actuator (162B) is adapted to move the second cutting tool (169) to perform a cutting operation. In some non-limiting forms of the second automated method, the automated actuator (162B) operably associated with the second cutting tool (169) is a trimming frame (144) or includes a trimming frame (144) and a trimming head (145).

[0089] like Figure 1-10 、 Figure 14-23As shown in FIG25, a second automated method (2000) for trimming a multi-ply structure (110) is further provided, the multi-ply structure (110) including a first ply (120) including at least a first composite material (125) and a second ply (130) including a second composite material (135). The second automated method (2000) includes, at block 2100, positioning a film (142) above a platen (140). The second automated method (2000) further includes, at block 2200, positioning a cutting board (152) above a protected portion (20) of the film (142). The second automated method (2000) further includes, at block 2300, applying the first ply (120) to the platen (140) using a laminator (170) such that the cutting board (152) is located between the protected portion (20) of the film (142) and an overlying portion (40) of the first ply (120). The second automated method (2000) further includes, at block 2400, cutting the overlying portion (40) of the first ply (120). The second automated method (2000) further includes, at block 2500, positioning a cutting plate (152) above the protected portion (20) of the first ply (120). The second automated method (2000) further includes, at block 2600, applying the second ply (130) to the platen (140) using the laminator (170) such that the cutting plate (152) is positioned between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130). The second automated method (2000) further includes, at block 2700, cutting the overlying portion (40) of the second ply (130).

[0090] Continue to refer Figure 13-23 In some instances, the second automated method includes positioning the film (142) over the platen (140) prior to applying the first ply (120). For example, Figure 14 Illustrated is a membrane (142) positioned above a platen (140).

[0091] Some non-limiting forms of the latter second automated method further include positioning a cutting plate (152) over the protected portion (20) of the film (142) prior to applying the first ply (120). For example, Figure 14 Illustrated is the positioning of a cutting plate (152) over the protected portion (20) of the film (142) prior to application of the first ply (120). Figure 14 Also illustrated is positioning a second cutting plate (182) over the protected portion (20) of the film (142) prior to applying the first ply (120).

[0092] In some non-limiting forms of the latter second automated method, applying the first ply (120) is performed such that the cutting plate (152) and the second cutting plate (182) are each between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120). For example, Figure 15 The first ply (120) is illustrated as being applied such that the cutting panel (152) and the second cutting panel (182) are each between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120).

[0093] In some non-limiting forms of the latter second automated method, cutting the overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply is performed after the first ply (120) is applied over the platen (140). In some examples, the latter cutting is performed before positioning the cutting plate (152) or the second cutting plate (182) over the protected portion (20) of the first ply (120). For example, Figure 16 Illustrated is cutting of an overlying portion (40) of a first ply (120) to produce a first scrap (124) and a second scrap (134) from the first ply after the first ply (120) is applied over a platen (140) and before a cutting plate (152) is positioned over a protected portion (20) of the first ply (120).

[0094] In some non-limiting forms of the latter second automated method, discarding the first waste material (124) and the second waste material (134) from the first ply (120) is performed after cutting the overlying portion (40) of the first ply (120). In some examples, the latter discarding is performed before positioning the cutting plate (152) over the protected portion (20) of the first ply (120). For example, Figure 17 Illustrated is the discarding of first waste (124) and second waste (134) from the first ply (120) after cutting the overlying portion (40) of the first ply (120) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120).

[0095] In some non-limiting forms of the latter second automated method, positioning the cutting plate (152) and the second cutting plate (182) is performed by rotating the cutting plate (152) about a first rotation axis (156) and by rotating the second cutting plate (182) about a second rotation axis (186). For example, Figure 18A -C illustrates positioning the cutting plate (152) and the second cutting plate (182) performed by rotating the cutting plate (152) about the first rotation axis 156 and by rotating the second cutting plate (182) about the second rotation axis (186).

[0096] In some non-limiting forms of the latter second automated method, applying the second ply (130) over the platen (140) is performed such that the cutting plate (152) and the second cutting plate (182) are each between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130). For example, Figure 19-22 The second layer (130) (see Figure 21 ) is applied over the platen (140) such that the cutting plate (152) and the second cutting plate (182) are each between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130).

[0097] In some non-limiting forms of the latter second automated method, cutting of the overlying portion (40) of the second ply (130) is performed. For example, Figure 21 Cutting of the overlying portion (40) of the second ply (130) is illustrated.

[0098] In some non-limiting forms of the latter second automated method, the first waste material (124) and the second waste material (134) from the second ply are discarded. For example, Figure 22 Discarding of second waste (134) from the second ply is illustrated.

[0099] Now refer to Figure 23 In some non-limiting examples, the platen (140) is movable between multiple workstations (10), transporting the ply or ply structure (110) from one workstation (10) to another workstation (10′), and supporting the ply or ply structure (110) in the workstation (10) while operations are performed thereon.

[0100] Furthermore, the present disclosure includes implementations according to the following clauses:

[0101] Clause 1. An automated method for trimming a multi-ply structure (110) comprising at least a first ply (120) and a second ply (130), the method comprising:

[0102] applying a first ply (120) over a platen (140);

[0103] positioning a cutting plate (152) over the protected portion (20) of the first ply (120);

[0104] applying the second ply (130) over the platen (140) such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130); and

[0105] The overlying portion (40) of the second ply (130) is cut.

[0106] Clause 2. The automated method of Clause 1, further comprising positioning the film (142) above the platen (140) prior to applying the first ply (120).

[0107] Clause 3. The automated method of Clause 2, further comprising positioning a cutting plate (152) over the protected portion (20) of the film (142) prior to applying the first ply (120).

[0108] Clause 4. The automated method of clause 3, wherein applying the first ply (120) is performed such that the cutting plate (152) is positioned between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120).

[0109] Clause 5. The automated method of clause 4, further comprising cutting an overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply after applying the first ply (120) over the platen (140) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120).

[0110] Clause 6. The automated method of clause 5, further comprising discarding first waste material (124) from the first layer of sheet (120) after cutting the overlying portion (40) of the first layer of sheet (120) and before positioning the cutting plate (152) over the protected portion (20) of the first layer of sheet (120).

[0111] Clause 7. The automated method of clause 5 or clause 6, wherein cutting the overlying portion (40) of the first layer (120) comprises moving the cutting tool (160) relative to the first layer (120), and wherein cutting the overlying portion (40) of the second layer (130) comprises moving the cutting tool (160) relative to the second layer (130).

[0112] Clause 8. The automated method of clause 7, wherein the cutting tool (160) is operably engaged with the automated actuator (162).

[0113] Clause 9. The automated method of clause 7 or clause 8, wherein the cutting tool (160) comprises one or more of an ultrasonic knife (163), a mechanical knife (165), and a gear cutter (167).

[0114] Clause 10. The automated method of any of Clauses 1 to 9, wherein cutting the overlying portion (40) of the second ply (130) produces second waste (134) from the second ply.

[0115] Clause 11. The automated method of Clause 10, further comprising discarding second waste material (134) from the second ply.

[0116] Clause 12. The automated method of any of clauses 1 to 11, wherein applying the first ply (120) over the platen (140) comprises using a laminator (170) movable with respect to the platen (140).

[0117] Clause 13. The automated method of any of Clauses 1 to 12, wherein the first ply (120) comprises a first composite material (125).

[0118] Clause 14. The automated method of Clause 13, wherein the first composite material (125) comprises a first polymer matrix (126) and first reinforcing fibers (128).

[0119] Clause 15. The automated method of Clause 14, wherein the first polymer matrix (126) comprises a thermosetting resin (127).

[0120] Clause 16. The automated method of Clause 14 or Clause 15, wherein the first reinforcing fibers (128) comprise carbon fibers (129).

[0121] Clause 17. The automated method of any of Clauses 13 to 16, wherein the second ply (130) comprises a second composite material (135).

[0122] Clause 18. The automated method of Clause 17, wherein the second composite material (135) comprises a second polymer matrix (136) and second reinforcing fibers (138).

[0123] Clause 19. The automated method of Clause 18, wherein the second polymer matrix (136) comprises a thermosetting resin (127).

[0124] Clause 20. The automated method of Clause 18 or Clause 19, wherein the second reinforcing fibers (138) comprise carbon fibers (129).

[0125] Clause 21. The automated method of any of clauses 17 to 20, wherein the second composite material (135) is substantially the same as the first composite material (125).

[0126] Clause 22. The automated method of any of clauses 1 to 21, wherein positioning the cutting plate (152) above the protected portion (20) of the first layer of sheet (120) comprises positioning the cutting plate (152) in direct contact with the protected portion (20) of the first layer of sheet (120).

[0127] Clause 23. The automated method of any of clauses 1 to 22, wherein the cutting plate (152) is connected to a swing arm (154), and wherein positioning the cutting plate (152) above the protected portion (20) of the first layer (120) includes rotating the swing arm (154) about a rotation axis (156).

[0128] Clause 24. The automated method of clause 23, wherein rotating the swing arm (154) is accomplished by an automated actuator (162).

[0129] Clause 25. The automated method of clause 23, further comprising sliding the swing arm (154) about the rotation axis (156) using the slot (158).

[0130] Clause 26. The automated method of any of clauses 1 to 25, wherein applying the second ply (130) over the platen (140) comprises using a laminator (170) movable with respect to the platen (140).

[0131] Clause 27. The automated method of any of clauses 1 to 26, further comprising moving the platen (140) into the workstation (10).

[0132] Clause 28. The automated method of any one of clauses 1 to 21, further comprising:

[0133] positioning a second cutting plate (182) over the second protected portion (24) of the first ply (120) such that the second cutting plate (182) is between the second protected portion (24) of the first ply (120) and the second overlying portion (44) of the second ply (130); and

[0134] A second overlying portion (44) of the second ply (130) is cut.

[0135] Clause 29. The automated method of Clause 28, wherein cutting the second overlying portion (44) of the second ply (130) comprises moving a second cutting tool (169) relative to the second ply (130).

[0136] Clause 30. An automated method for trimming a ply structure (110) comprising at least a first ply (120) comprising a first composite material (125) and a second ply (130) comprising a second composite material (135), the method comprising:

[0137] positioning a membrane (142) above a platen (140);

[0138] positioning a cutting plate (152) over the protected portion (20) of the membrane (142);

[0139] applying the first ply (120) over the platen (140) using a laminator (170) such that the cutting plate (152) is positioned between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120);

[0140] cutting an overlying portion (40) of the first layer (120);

[0141] positioning a cutting plate (152) over the protected portion (20) of the first ply (120);

[0142] applying the second ply (130) over the platen (140) using a laminator (170) such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130); and

[0143] The overlying portion (40) of the second ply (130) is cut.

[0144] Clause 31. An automated multilayer sheet structure (110) trimming system (15), comprising

[0145] platen(140);

[0146] a laminator (170) movable relative to the platen (140) to apply at least a first ply (120) and a second ply (130) above the platen (140);

[0147] a cutting plate (152) movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130); and

[0148] A cutting tool (160) is movable with respect to the platen (140) for cutting the second ply (130).

[0149] Clause 32. The system (15) of clause 31, further comprising a membrane (142) positioned above the platen (140).

[0150] Clause 33. The system (15) of clause 31 or clause 32, wherein the cutting plate (152) is movable relative to the platen (140) about an axis of rotation (156).

[0151] Clause 34. The system (15) of any one of clauses 31 to 33, further comprising a waste bin (16) positioned to receive second waste (134) generated from the second ply (130).

[0152] Clause 35. The system (15) of any one of clauses 31 to 34, further comprising an automated actuator (162) operably associated with the cutting tool (160).

[0153] Clause 36. The system (15) of any one of clauses 31 to 35, wherein the cutting tool (160) comprises one or more of an ultrasonic knife (163), a mechanical knife (165), and a gear cutter (167).

[0154] Clause 37. The system (15) of any one of clauses 31 to 36, further comprising:

[0155] A second cutting plate (182) is movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130).

[0156] Although various examples of the disclosed apparatus and methods have been shown and described, modifications may occur to one skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

1. An automated method for trimming a multi-ply structure (110) comprising at least a first ply (120) and a second ply (130), the method comprising: applying the first ply (120) over a platen (140); at least one of automatically rotating the cutting plate (152) about a rotational axis (156) and linearly moving the cutting plate (152) relative to the platen (140) perpendicular to the rotational axis (156) to position the cutting plate (152) over the protected portion (20) of the first ply (120); applying the second ply (130) over the platen (140) such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130); and The overlying portion (40) of the second ply (130) is cut.

2. The automated method of claim 1, further comprising positioning a film (142) above the platen (140) prior to applying the first ply (120).

3. The automated method of claim 2, further comprising positioning a cutting plate (152) over the protected portion (20) of the film (142) prior to applying the first ply (120).

4. The automated method of claim 3, wherein applying the first ply (120) is performed such that the cutting plate (152) is located between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120).

5. The automated method of claim 4 , further comprising cutting an overlying portion (40) of the first ply (120) to produce a first scrap (124) from the first ply after applying the first ply (120) over the platen (140) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120).

6. The automated method of claim 5, further comprising discarding first waste material (124) from the first ply (120) after cutting the overlying portion (40) of the first ply (120) and before positioning the cutting plate (152) over the protected portion (20) of the first ply (120).

7. An automated method according to claim 5 or claim 6, wherein cutting the overlying portion (40) of the first layer (120) includes moving the cutting tool (160) relative to the first layer (120), and wherein cutting the overlying portion (40) of the second layer (130) includes moving the cutting tool (160) relative to the second layer (130).

8. The automated method of claim 7, wherein the cutting tool (160) is operably engaged with an automated actuator (162).

9. The automated method according to claim 7, wherein the cutting tool (160) comprises one or more of an ultrasonic knife (163), a mechanical knife (165), and a gear cutter (167).

10. The automated method of claim 1, wherein cutting the overlying portion (40) of the second ply (130) produces second waste (134) from the second ply.

11. The automated method of claim 10, further comprising discarding second waste material (134) from the second ply.

12. The automated method of claim 1, wherein applying the first ply (120) over the platen (140) comprises using a laminator (170) movable with respect to the platen (140).

13. The automated method of claim 1, wherein the first ply (120) comprises a first composite material (125).

14. The automated method of claim 13, wherein the first composite material (125) comprises a first polymer matrix (126) and first reinforcing fibers (128).

15. The automated method of claim 14, wherein the first polymer matrix (126) comprises a thermosetting resin (127).

16. The automated method of claim 14 or claim 15, wherein the first reinforcing fibers (128) comprise carbon fibers (129).

17. The automated method of claim 13, wherein the second ply (130) comprises a second composite material (135).

18. The automated method of claim 17, wherein the second composite material (135) comprises a second polymer matrix (136) and second reinforcing fibers (138).

19. The automated method of claim 18, wherein the second polymer matrix (136) comprises a thermosetting resin (127).

20. The automated method of claim 18 or claim 19, wherein the second reinforcing fibers (138) comprise carbon fibers (129).

21. The automated method of any one of claims 17 to 19, wherein the second composite material (135) is the same as the first composite material (125).

22. The automated method of claim 1, wherein positioning the cutting plate (152) over the protected portion (20) of the first ply (120) comprises positioning the cutting plate (152) in direct contact with the protected portion (20) of the first ply (120).

23. The automated method of claim 1, wherein the cutting plate (152) is connected to a swing arm (154), and wherein the cutting plate (152) is positioned above the protected portion (20) of the first ply (120) by automatically rotating the swing arm (154) about the rotation axis (156).

24. The automated method of claim 23, wherein rotating the swing arm (154) is accomplished by an automated actuator (162).

25. The automated method of claim 23, wherein the cutting plate (152) is positioned over the protected portion (20) of the first ply (120) by automatically sliding the swing arm (154) about the rotation axis (156) using a slot (158).

26. The automated method of claim 1, wherein applying the second ply (130) over the platen (140) comprises using a laminator (170) that is movable with respect to the platen (140).

27. The automated method of claim 1, further comprising moving the platen (140) into the workstation (10).

28. The automated method of claim 1, further comprising: positioning a second cutting plate (182) over the second protected portion (24) of the first ply (120) such that the second cutting plate (182) is between the second protected portion (24) of the first ply (120) and the second overlying portion (44) of the second ply (130); and A second overlying portion (44) of the second ply (130) is cut.

29. The automated method of claim 28, wherein cutting the second overlying portion (44) of the second ply (130) comprises moving a second cutting tool (169) relative to the second ply (130).

30. An automated method for trimming a ply structure (110) comprising at least a first ply (120) comprising a first composite material (125) and a second ply (130) comprising a second composite material (135), the method comprising: positioning a membrane (142) above a platen (140); positioning a cutting plate (152) over the protected portion (20) of the membrane (142); applying the first ply (120) over the platen (140) using a laminator (170) such that the cutting plate (152) is positioned between the protected portion (20) of the film (142) and the overlying portion (40) of the first ply (120); cutting an overlying portion (40) of the first layer (120); positioning a cutting plate (152) over the protected portion (20) of the first ply (120); applying the second ply (130) over the platen (140) using a laminator (170) such that the cutting plate (152) is located between the protected portion (20) of the first ply (120) and the overlying portion (40) of the second ply (130); and The overlying portion (40) of the second ply (130) is cut.

31. An automated multi-layer sheet structure (110) trimming system (15), comprising platen(140); a laminator (170) movable relative to the platen (140) to apply at least a first ply (120) and a second ply (130) above the platen (140); a swing arm (154) having a rotation axis (156); a cutting plate (152) connected to the swing arm (154) and rotatably movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130); and A cutting tool (160) is movable with respect to the platen (140) for cutting the second ply (130).

32. The system (15) of claim 31, further comprising a membrane (142) positioned above the platen (140).

33. The system (15) of claim 31 or claim 32, wherein the cutting plate (152) is linearly movable relative to the platen (140) in a direction perpendicular to the rotational axis (156).

34. The system (15) of claim 31 or claim 32, further comprising a waste bin (16) positioned to receive second waste (134) generated from the second ply (130).

35. The system (15) of claim 31 or claim 32, further comprising an automated actuator (162) operatively associated with the cutting tool (160).

36. The system (15) of claim 31 or claim 32, wherein the cutting tool (160) comprises one or more of an ultrasonic knife (163), a mechanical knife (165), and a gear cutter (167).

37. The system (15) of claim 31 or claim 32, further comprising: A second cutting plate (182) is movable relative to the platen (140) and positionable between the first ply (120) and the second ply (130).

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