patch lay-up using dedicated machine simulation software. This way, the coordinated motions of both robots are calculated and the whole manufacturing process is then simulated to avoid collisions. Contour fitting Illustration of partial Ply coverage with patches Profile view of patch laminate tape is then cut into long fibre segments called patches (2). The correct patch geometry is ensured by an optical system that scraps imperfect ones (3). An end-effector mounted on the pick-and-place robot picks up the patch by vacuum (4). The position of the patch on the end-effector is checked by a second optical system that detects any deviation in order to correct the patch deposition point (5). The end-effector is highly flexible and deforms according to the tool surface. It includes a heating system to activate the binder material for preform fixation. The mould is manipulated by a six-axis robot enabling 3D preforming (6).The extremely quick movement of the pick-and-place robot ensures high productivity. The sequentiallystacked patches eventually create the 3D preform. Software integration Catia its market success. To ensure simple and efficient use of the FPP hardware by any user, a series of software modules is provided by the software and process consulting company Cenit. These modules ensure a simple and efficient utilization of the FPP technology. The first module is the dedicated FPP design module, integrated in the Catia V5 CPD workbench supporting the development of the FPP specific laminate. It uses CAD functionalities to automatically arrange several layers of patches on a complex three-dimensional surface. An algorithm optimizes the arrangement of the patch based on user-provided input criteria. After the optimization process, the calculated laminate arrangement is visualized in the software. The second module ensures offline programming of the machine control for the Since all patches are of the same size, a given ply contour will not necessarily be filled without generating gaps or overlaps. The applicator can decide whether it is preferable to leave a gap at the lay-up edge or if the boundary should be exceeded. The software user can specify the filling parameter for patches at the contour at a value between 0% and 100% of the patch area. Laminate optimization In contrast to an endless fibre material, an FPP layer contains butt splices between all patches. To produce a structure with high mechanical properties, it is necessary to vary the position of the splices from layer to layer. The effect of different staggering patterns on the failure mechanism and the laminate strength was closely investigated at the LCC. The results are incorporated into an optimization algorithm that automatically shifts the individual layers to optimize the laminate properties. Guide curves As the FPP technology allows steering Hardware The first commercially produced FPP equipment is located in the Institute for Carbon Composites (LCC) at the Technische Universität München. The material processed is a 20 mm wide, 80 g/m² dry fibre tape from the material supplier Oxeon. It is cut into 40-65 mm long patches with either a round or rectangular shape. The quality inspection guarantees the compliance with tolerances of ± 0.2 mm in length and width. The pickand-place robot reaches a deposition rate of one patch per second while the tool is moved independently. The second optical system ensures a positioning repeatability of ±0.3 mm. Software development The ease of use of a technology is crucial for Process simulation No87 March 2014 / jec composites magazine 109