Automated Tape Relaying to monitor and control first-ply deposition

A real-time control algorithm, the “Automated Tape Relaying” (ATR) approach, was developed and validated for improving in-process quality control and material characterisation processes within Automated Fibre Placement (AFP). The algorithm operates by monitoring the deposited tape using onboard laser line scanners. If the tape height is out-of-tolerance, the machine reacts by reversing the AFP deposition process and redepositing the tape with modified process parameters. This approach can also be used for characterisation of AFP pre-preg to determine process settings for in-tolerance deposition. The results showed that single and multi parameter definition was possible. The ATR approach supports faster materials-process exploration using less material, and could be scaled-up to industrial AFP processes with further investment.