Increased Composite Hand-Layup Repeatability Using End-End Design And Manufacture Simulation Software

Hand layup is still the dominant forming process for the creation of the widest range of complex geometry and mixed material composite parts. However, this process is still poorly controlled and informed, limiting productivity. This paper seeks to address this issue by demonstrating a methodology for simulation based composite manufacture process development and control, improving the standardisation of produced components. Current methodologies and future trends are presented. A Case study is developed, typical of the complex geometry found in many difficult-to-manufacture composite parts. Drapeability is assessed by the use of FiberSIM composite manufacturing software. The tool is then broken into zone based features and production control outputs derived including ply-books, projection arrays and job plans. Laminates are manufactured by a range of laminators before and after the implementation of the digital outputs. The implementation of the digital tools shows a significant reduction in ply deviation and consistency in part weight. Digital tools are also shown to support inexperienced laminators in production confidence and part consistency. The integration of digital manufacturing techniques for hand-layup manufacturing will be instrumental in the future of augmenting manual labour with appropriate automation.