Automated Composite Patch Fabrication via 3D Mapping
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Solution Overview
Problem
Current methods for fabricating composite patches to rework composite structures are time-consuming, labor-intensive, and prone to human error, leading to inconsistencies in fitment and alignment due to manual measurement and cutting processes.
Innovation Solution
The use of additive manufacturing under computer control to produce composite laminate rework/repair patches, where a 3-D map of the reworked area is generated and used to produce plies with precise dimensions and orientations, reducing human intervention and enhancing fitment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual measurement and cutting processes are used to fabricate composite patches, then flexibility and adaptability are maintained, but manufacturing precision and consistency deteriorate due to human error
Solution Approach 1:
The patent replaces manual mechanical measurement and cutting processes with automated computer-controlled cutting systems. The control system receives digital design data and automatically controls the cutting tool to fabricate patches with precise dimensions and complex geometries, eliminating human error in measurement and cutting while maintaining the ability to adapt to different repair scenarios through software programming.
Solution Approach 2:
The patent uses digital copying of the original structure's geometry through 3D scanning or CAD models to create accurate digital templates. These digital copies are then used to generate cutting paths and patch designs, ensuring that each patch precisely matches the required geometry without manual measurement errors, while the digital data can be reused consistently across multiple patches.
2Manufacturing precision
If automated computer-controlled cutting is used to produce patches, then manufacturing precision and consistency are improved, but device complexity and initial setup requirements increase
Solution Approach 1:
The patent employs a universal computer-controlled cutting system that can handle multiple patch types, geometries, and materials through software programming rather than dedicated equipment for each task. The system uses standardized digital data formats and can be reconfigured for different repair scenarios by loading different design files, reducing the need for multiple specialized devices while maintaining high precision across all applications.
3Productivity
If hand labor is used to orient and stack patch plies, then process flexibility is maintained, but productivity and consistency deteriorate due to variability in manual operations
Solution Approach 1:
The patent replaces manual orientation and stacking of patch plies with automated handling systems controlled by computer software. The system automatically positions each ply according to the digital design data, ensuring consistent orientation and alignment without the variability inherent in manual operations, while the software can be programmed to handle different ply sequences and configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces human error and improves the consistency and accuracy of patch fitment, enabling precise alignment and installation of patches that match the topography of the reworked area, thereby enhancing the quality and reliability of the rework process.
Implementation Method 1
The rework patch is produced by additive manufacturing, layer-by-layer. The additive manufacturing may be performed by one of 3-D printing, stereolithography, fused deposition modeling, and selective laser sintering.
Implementation Method 2
Aligning the nanotubes is performed by subjecting the nanotubes to an electromagnetic field.
Data Source
AI summary
An area of a composite laminate structure is reworked by scarfing the area, generating a 3-D map of the scarfed area, and installing a rework patch that is built based on the 3-D map.