Zonal Lamination for Faster Composite Layup on Moving Mandrels

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Solution Overview

Problem

Existing methods for fabricating large composite parts, such as those used in aircraft components, require substantial time due to the need for a single AFP machine to traverse the entire part, leading to inefficiencies in production time and space utilization.

Innovation Solution

The method involves subdividing the laminate into zones and using multiple lamination heads to lay up fiber-reinforced material simultaneously while splicing the zones together, allowing the layup mandrel to move in a process direction during fabrication, enhancing production speed and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a single AFP machine traverses the entire part singularly, then manufacturing precision is maintained, but production time increases substantially

Engineering Contradiction:

Improvelaminate qualityVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The laminate is divided into multiple zones along the process direction, with each zone assigned to a different lamination head. This segmentation allows multiple lamination heads to operate simultaneously on different portions of the laminate, dramatically reducing the total production time while maintaining quality through controlled zone boundaries and splices.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a single-point traversal to a multi-point parallel processing approach by introducing the process direction as a new dimension for zone division. Lamination heads operate in parallel across different zones simultaneously, converting sequential processing into parallel processing to enhance productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If a single AFP machine is used, then device complexity is low, but layup time increases substantially

Engineering Contradiction:

Improvelamination system structureVSAvoidlayup time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The lamination system is segmented into multiple independent lamination heads, each capable of operating autonomously on different zones. This segmentation enables parallel processing and reduces layup time, with the added complexity managed through zone management and splice coordination mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple lamination heads operate continuously in parallel on different zones simultaneously, eliminating the idle time inherent in sequential single-machine operation. The layup mandrel continues moving through the process direction while multiple heads work concurrently, maximizing productive time.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If the layup mandrel remains stationary, then manufacturing precision is easier to control, but production efficiency decreases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The layup mandrel transitions from a stationary platform to a moving platform that progresses through the process direction during fabrication. This dynamic movement enables continuous production flow and reduces transit time, while positioning accuracy is maintained through coordinated control of the mandrel's movement and lamination head positioning.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The moving mandrel enables continuous progression of the laminate through the lamination process without stationary waiting periods. Multiple lamination heads operate concurrently on different zones while the mandrel moves, creating continuous productive action that enhances both efficiency and throughput.

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If multiple lamination heads operate in tandem, then production speed increases, but device complexity increases

Engineering Contradiction:

Improveproduction speedVSAvoidmultiple lamination heads coordination

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the laminate into discrete zones with dedicated lamination heads for each zone, simplifying coordination through clear zone ownership. The segmented approach allows independent operation of each lamination head while maintaining overall system coordination through zone boundary management and splice sequencing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Zone boundaries and splice interfaces act as intermediaries that coordinate the operations of multiple lamination heads. These intermediary elements provide structured interaction points that manage the complexity of parallel operation by establishing clear protocols for zone handoffs and splice timing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250256471A1Zonal Lamination for Composite Parts in a Moving Line

Publication Date: 2025.08.14 THE BOEING CO

AI summary

An apparatus and system is provided for fabricating composite parts. The system includes subdividing a laminate into zones, laying up tows of fiber reinforced material for the laminate over a layup mandrel via multiple laminations such that each lamination head applies tows in a different zone, and splicing the zones together to form the laminate during the laying up of the tows while moving the layup mandrel in a process direction during fabrication of the composite parts.