Application of AFP to structural aerospace components utilising out of autoclave materials

Automated fibre placement technology (AFP) offers improved cycle times; greater process reliability and reduced scrap material when compared to traditional hand lay up. Despite this, widespread application of AFP is limited by the high cost and low flexibility of production equipment. However, recent advances in robotic mounted fibre placement systems potentially offer a flexible and affordable solution that could be utilised by the aerospace supply chain. The objective of this work was to assess the feasibility of the current generation robot mount AFP systems. A series of experimental standard feature trials was performed to characterise and optimise the AMRC’s Automated Dynamics AFP system. A demonstrator component was then manufactured, utilising out of autoclave (OoA) material, as a case study exercise for cost and life cycle analysis. The study showed that with improvements to system reliability, AFP offers an attractive solution for composites manufacture.