Tape Deposition Platform for Precise Multi-Pass Lay-Up

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Solution Overview

Problem

The manual laying up of pliable sheets of material, such as carbon fibre preforms, boat sails, and garments, is labor-intensive, costly, and results in inconsistent products due to handling difficulties and waste generation from inaccurate cutting, leading to discomfort for workers and variability in the final product.

Innovation Solution

A tape deposition system comprising a moveable platform with a deposition surface and a tape deposition head that applies lengths of tape along a deposition direction, allowing for precise and automated alignment of sheets by moving the platform around a closed path, enabling multiple applications of tape to create complex lay-ups efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If sheets of material are cut from larger pieces to desired shapes, then the desired shape can be obtained, but significant waste material is generated

Engineering Contradiction:

Improvedesired shapeVSAvoidwaste material

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The material is supplied as pre-cut tapes of specific widths and lengths that match the required sheet dimensions. Instead of cutting from large sheets, the material is segmented into exact-size tapes before deposition, eliminating waste from oversizing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tapes are pre-cut to the exact dimensions and shapes required for the final product before being deposited. This preliminary preparation of material to precise specifications prevents the need for waste-generating cutting operations during assembly.

Inventive Principle:

Principle #10Preliminary action

2Shape

If sheets are cut from larger material pieces, then the desired shape can be achieved, but cutting accuracy may be insufficient leading to product inconsistency

Engineering Contradiction:

Improvedesired shapeVSAvoidcutting accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

Material is divided into pre-cut tapes with precise dimensions and shapes manufactured to high tolerances. This segmentation into precision-cut components eliminates variability from on-demand cutting operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Tapes are pre-manufactured to exact specifications before use. This preliminary precision manufacturing ensures consistent dimensions and shapes are achieved before the materials are assembled, eliminating cutting accuracy issues during production.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If manual laying up of sheets is performed, then complex lay-up requirements can be met, but the process is labor-intensive and expensive

Engineering Contradiction:

Improvecomplex lay-up requirementsVSAvoidlabor intensity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system uses a moveable platform that can rotate and translate dynamically to position tapes at various orientations and locations. This dynamic positioning capability enables complex lay-up patterns to be achieved automatically, replacing manual labor while maintaining design flexibility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Manual mechanical laying up operations are replaced with an automated tape deposition system that uses controlled movement of the platform and precise tape application. This substitution of automated mechanical systems for manual operations reduces labor intensity while maintaining the ability to meet complex lay-up requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Shape

If manual handling of pliable sheets is performed, then sheets can be positioned, but handling difficulties arise due to size and pliability

Engineering Contradiction:

Improvesheet positioningVSAvoidhandling difficulty

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The handling difficulties are eliminated by extracting the material from sheet form and supplying it as narrow tapes. These tapes are rigid enough to be handled easily by the deposition system yet can be positioned to form the required sheet shapes when assembled, removing the pliability handling problem.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12533857B2Tape deposition system

Publication Date: 2026.01.27 MCLAREN AUTOMOTIVE LTD

AI summary

A tape deposition system, the system comprising: a platform moveable around a closed path in a first direction, the platform having a deposition surface; and a tape deposition head configured to apply lengths of tape along a deposition direction to the deposition surface, the platform being moveable past the deposition head around the closed path along the deposition direction to apply lengths of tape to the deposition surface; and wherein the system is configured to move the platform around the path multiple times to permit multiple lengths of tape to be applied to the deposition surface.