Laser Machining Freely Arranged Composite Parts
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Solution Overview
Problem
Current methods for perforating composite materials used in aircraft acoustic panels are inefficient, as they require extensive tooling and precise location, leading to high setup times and costs, and are not well-suited for forming thousands to millions of small holes accurately and quickly.
Innovation Solution
A laser machining system that freely arranges composite parts on a support surface, using a scanning system to determine location and geometry, and a laser system to form apertures without touching the part, reducing the need for tooling and allowing the composite to slide unencumbered, thus enabling fast and accurate perforation without excessive force or alteration of the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical drilling methods are used to perforate composite face skins, then holes can be formed, but extensive tooling and precise location fixtures are required, leading to high setup times and costs
Solution Approach 1:
The patent replaces traditional mechanical drilling systems with a laser-based system. The laser beam delivers energy to ablate material and form holes without physical contact, eliminating the need for mechanical drill bits, tooling fixtures, and location devices. This substitution of mechanical energy with optical energy directly resolves the contradiction by simplifying the device while maintaining or improving productivity.
Solution Approach 2:
The patent introduces a laser beam as an intermediary between the control system and the composite material. Instead of direct mechanical contact requiring complex tooling, the laser beam acts as a non-contact intermediary that can be precisely directed to form holes. This intermediary approach eliminates the need for physical tooling while enabling rapid perforation.
2Manufacturing precision
If traditional drilling methods are used, then holes are formed, but the parts require extensive tooling and precise location, increasing setup time
Solution Approach 1:
The patent replaces mechanical positioning and drilling systems with a laser-based system controlled by digital coordinates. The laser beam can be precisely positioned using galvanometer mirrors or other optical positioning mechanisms, achieving high hole placement accuracy without requiring physical fixtures, templates, or location devices. This eliminates time-consuming setup procedures while maintaining manufacturing precision.
Solution Approach 2:
The patent changes the fundamental parameter of material removal from mechanical force to thermal energy. By using laser energy to ablate material, the system achieves precise hole placement through optical control and digital positioning rather than mechanical fixtures. This parameter change enables rapid setup with high precision, as the laser system can be quickly repositioned and reprogrammed for different hole patterns without physical tooling changes.
3Manufacturing precision
If conventional machining methods are used on composite materials, then material is removed, but excessive force alters the material structure
Solution Approach 1:
The patent replaces mechanical drilling force with laser energy. The laser beam delivers concentrated thermal energy to the composite material, causing localized ablation and vaporization of material. This non-contact energy delivery method eliminates mechanical stress, pressure, and force that would otherwise distort or damage the composite structure. The result is precise hole formation that preserves material integrity without excessive applied force.
Solution Approach 2:
The patent utilizes phase transitions of material from solid to vapor through laser heating. The laser energy rapidly heats the composite material at the target location, causing the material to undergo phase transition and be ejected as vapor or debris. This thermal mechanism replaces mechanical force-based removal, preventing structural alteration while achieving clean, precise holes that maintain surrounding material integrity.
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 method significantly reduces setup time and costs by eliminating the need for tooling and minimizes material alteration, enabling precise and efficient formation of perforations in composite materials, such as those used in aircraft acoustic panels, while maintaining the structural integrity of the parts.
Implementation Method 1
a laser system to form apertures without touching the part
Implementation Method 2
forming one or more apertures in and/or cutting the freely arranged composite part
Data Source
Figure 1
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Figure 5
AI summary
Manufacturing methods are provided. During one of these manufacturing methods, a composite part 22 is freely arranged on a support surface. The freely arranged composite part 22 is scanned using a scanning system to provide command data. The freely arranged composite part is machined using a laser 42 based on the command data.