JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017 - 30

MANUFACTURING automation
architecture and its main advantage is that
it can produce any part (rotating, complex,
easy parts, etc.). Robots are very versatile
as they can integrate different technologies
such as AFP, ATL, USCutter, NDI, etc.
Moreover, they are the ideal configuration
for R&D centres or very low part production rates.
Unlike classical machine tools, robots are
not limited in the travel axis as they can
virtually access any point within 2 metres
from the main axis. If the longitudinal (X)
axis is included, the robot can virtually
manufacture any part. This capability is
of extreme importance in R&D centres
where part geometry is typically changed
on a weekly or daily basis.
If the robot is equipped with a second
head (for example the ATL head shown
in Figure 9), it can virtually manufacture
any part located within an aircraft, at least
for the primary structure. It may not be
the fastest machine compared to classical
machine tools, but it can definitely do
everything.
As highlighted in the previous paragraphs,
changing heads provides greater flexibility to the manufacturing cell. MTorres
started changing ATL heads back in 2012,
switching to AFP heads in 2014, so it was
a logical step to change ATL-AFP heads
in 2015. The next steps are to be defined,
but they may include the ability to change
other technology heads such as NDI or
trimming heads.
ATL-AFP business case
At the end of the day, we need to produce
a part, and flexibility is great to select the
right technology at the right time, but
when is it better to use ATL or AFP for a
wing skin?

30

Fig. 10: ATL vs AFP in wing skin

For large doublers and island doublers, the
use of AFP is "no brainer". For full plies,
AFP is faster (cut&add at 2400 ipm) but
the material cost of ATL is substantially
lower so ATL could be used to reduce the
cost of the final composite part. Flexibility
brings new opportunities for the manufacture of large composite structures.
Business case for future aircraft
There is uncertainty when thinking about
future business cases and several questions
arise.
Could we use this technology for a rate
of more than 60 small aircraft per month?
The answer would probably be yes, but this
would mean 240 skins per month, thus
roughly 1  skin every 2 hours.
Which material should we use from among
prepregs, dry fibres, non-crimp fabrics
(NCF) or thermoplastics?
Will we be able to reach 400 lbs/h with
AFP technology?
Will inspection devices be ready in the
near future?
We probably don't have the answer to
these questions yet, but what it is sure is
that flexibility will play a major role in the
next business cases.
Conclusion: exibility is here to stay
Today's business cases have to be revisited
for each part (almost every year). The latest
ATL and AFP technology has optimized
the way CFRP primary structures are
built. New aircraft programmes will likely
not require a specific machine dedicated
to the production of a single part but a
flexible machine for multiple parts.

jec composites magazine / N°117 November - December 2017

Changing head technology has enabled
AFP manufacturers to offer the right AFP
head for each application, using the right
tool for each part. The introduction of robot cells is "in fashion" due their relatively
low investment cost and huge flexibility,
making them very popular with Tier 2
suppliers.

More information:
www.mtorres.es
References
[1] Rapid Tape Laying for Large Structures. Luis Izco, SME/WESTEC 2003.
[2] Opportunities for Advanced
Composites Through Automated Fiber
Placement. CMR. Composite Market
Reports, 2006.
[3] Automated processes for composite
aircraft structures. Carroll Grant. Industrial Robot: An International Journal. 2006
Volume 33, Issue: 2, pages 117-121.
[4] High Speed Tow Placement System
for Complex Surfaces with Cut / Clamp &
Restart Capabilities at 85 m/min (3350
IPM). Luis Izco, Javier Isturiz, Manu
Motilva, 06AMT-41, SAE 2006 Toulouse.
[5] Trends in fiber placement technology.
Case study 2D stringer lamination. Luis
Izco, Manu Motilva, SAE 2009 Seattle.
[6] New AFP Machine Technology for
Lay-up Application of Specific Laminates.
Manu Motilva, SAE 2010 Wichita.
[7] A350XWB Fiber placement Spars.
From R&D conception phase to serial
production. Christopher Jones, Manu
Motilva, SAE 2011 Toulouse.
[8] Laser heating for Out of Autoclave
materials for fiber placement. Manu
Motilva, SAE 2012 Dallas.
[9] New developments in exchangeable
lamination platforms. Manu Motilva, SAE
2013 Montreal.
[10] AMTL. Automated Multi-Tape Layer,
a step forward on the ATL technology.
Javier Raya, Manu Motilva, SAE 2014
Madrid.
http://www.mtorres.es http://www.intermas-industry.com
Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #117 - November/December 2017
