JEC COMPOSITES MAGAZINE - Issue #56 - April 2010 - 36

SPECIAL jec composites show 2010
Metrology’s Laser Radar with known “as-designed” data taken from the composite design files. The TPC™ process then determines where the part is structurally deficient and by how much. TPC™ then automatically generates the appropriate number of compensation plies required to build a wing skin meeting engineering tolerances. These plies are then automatically nested and the NC program is generated for the ply cutting machine with MSI’s TruNEST™ application. In addition, MSI’s TruLASER™ View automatically creates laser projection files so a 3D laser projector can indicate the correct location for each ply as it is installed on the wing skin. The part is then ready to be re-cured to obtain final geometry. The finished composite part is then measured again with Nikon Metrology’s Laser Radar for geometry quality. Advantages or salient features: The CLC process offers many benefits. Lockheed Martin can accurately satisfy the difficult engineering specifications for composite parts while achieving an efficient manufacturing process that minimizes waste and increases throughput. The value created by this process is in immediate material savings, reduced aircraft weight and increased production throughput. The CLC process eliminates the need for sacrificial plies, which in turn saves composite material and reduces the weight of the aircraft. In addition, it prevents manufacturers from having to purchase large milling machines, which absorb facility costs and floor space requirements. By producing composite parts correctly the first time,

immediate savings can be made through minimizing waste and maximizing accuracy, part quality, and process efficiency. Cured Laminate Compensation is a sustainable/green production process for composite part manufacturing. Less scrap material is thrown away, the final products are built to operate more fuel efficiently and the facility footprint is reduced, requiring less energy. State of development: The process was developed specifically for the F-35 Joint Strike Fighter to test and correct the thickness of cured composite wing skins. It is being implemented at facilities currently responsible for the production of F-35 JSF wing skins, including Lockheed Martin in Ft. Worth, Texas; ATK Aerospace Structures in Clearfield, Utah; Alenia Aeronautica in Foggia, Italy; and ITT in Salt Lake City, Utah. More information: www.magestic.com

Finalist: Accudyne Systems, Inc. (USA)
Name: Accudyne Systems “part centric” approach to manufacture a “part purpose” machine. Description: A specific machine is developed to manufacture each different type of part, e.g. T, Z, or C stringers (see picture).

same time, a significantly reduced lead time could be achieved. This new process is intended for the highly automated production of large composite shells like aircraft fuselage panels. The main idea is to turn around the whole way of producing composite panels. Using a positive positioning device as counterpart to the female curing mould makes it possible to begin the panel manufacturing process with the last process step, the placement of the vacuum bag. Through a deep-drawing process, the vacuum bag can be formed into a complex contour with a high degree of repeatability. Additional elements like stringers and auxiliary materials can be positioned onto the preformed vacuum bag. The last step is the transfer of the whole preform to the curing mould by matching the positive and the female mould.

Finalist: CTC GmbH (Germany)
Partnership network: Airbus Operations GmbH (Germany); Premium Aerotec GmbH (Germany) Name: Autovac process Description: AutoVac is the first automated process for the whole composite panel production chain. Several manual steps like stringer placement, auxiliary materials placement or vacuum-bag sealing are eliminated, facilitating a very stable process with a high degree of reproducibility. At the `

jec composites magazine / No56 April 2010

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JEC COMPOSITES MAGAZINE - Issue #56 - April 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #56 - April 2010