High Rail Gantry - Wing Spars

Four high-rail gantry machine cells for laying up 1300+ pound in-situ wing spars of over 100 feet in length. Cells 3 and 4 were the first production implementation of the ½” ServoCreel AFP head. A robotic head-change system presents empty heads to an operator at a maintenance station, providing ergonomic access for cleaning and reloading, and without disrupting production.


High Rail Gantry - Wing Skins

Four high-rail gantry machine cells for laying up wing skins weighing over 5000 pounds. Each cell has a pair of OH20 (1.5” material, 20 lane) heads; cells 3 and 4 were the first production implementation of the 1.5” ServoCreel AFP head. An ECF head is shared between the cells, automating the disposition of expanded copper foil for lightning strike protection. A pendulum head-change system allows for offline cleaning and reloading without disrupting production.


AFP Robot Cell - Unspecified

EI Accurate Robot motion platform with 12m X-axis.

  • 1/8" 8 tow AFP
  • 1/2" 8 tow AFP
  • Probe
  • Horizontal rotator (15k lbs, 10ft diam. Parts)
  • Integrated laser projection

Fixed Beam Gantry - Engine Nacelles, Propulsion Components, and Thrust Reversers

Integrated multi machine production system for high part count production. System consists of two AFP gantries sharing the same bridge beam, with a shared head service area that is accessible by both machines and the head service robot. Machines are 0.5g capable motion platforms. System uses eight tow AFP heads for laying up inside of concave tools. System has four separate X axis pallets that allow for offline tool loading and unloading along with laser projection for manual inspection and repair operations. Each sled has an RFID reader for detecting what tool is loaded on the sled. This allows the machine to automatically load the correct programs and transform for that tool.

System includes four AFP heads, and a touch probe head. All heads are shared between the two gantry machines. The service robot moves heads into and out of the cell for machine use. The service robot also positions the head for ideal manual access in order to preform offline material loading and head service functions.


High Rail Gantry - Rocket Payload Fairing

The system has a 7th axis (C') to supplement the more conventional six axes (X, Y, Z, A, B, C) to access the complex curvature in the nose cone area. The machine is equipped with a Q16 head (1/4" x 16 tows) for all of the fairing and adapter parts. The machine is also equipped with an ATL head for production flat charges.


Robotic AFP/ATL Hybrid Cell

Location: National Composites Centre, Bristol, UK
Part Type: Various R&D

This project included an EI Accurate Robot motion platform with 15m X-axis travel.

  • 1/2" 8-tow AFP
  • Variable Size ATL (75mm, 200mm, 300mm)
  • Ultrasonic Cutting and Probe

For rotary components, the cell included a horizontal rotator for tools up to 9t and 4.6m diameter and a vertical turntable for parts up to 25t and 4.2m diameter.

A layup table facilitates material trials and machine calibration activities alongside any flat layup activity.

The cell operates as a flexible composite deposition environment accommodating a range of material types and formats to support R&D and preproduction activities.


AFP Robot Cell - Various R&D

EI Accurate Robot motion platform with 12m X-axis.

  • 1/4" 8 tow AFP
  • 1/2" 16 tow servo AFP
  • Probe
  • Custom Process Development head
  • 1/4" 16 tow AFP with laser heating (Q4 2020)

Ancillary equipment: Horizontal rotator (15k lbs, 10ft diam. Parts)

The cell operates as a flexible composite deposition environment to support R&D of new manufacturing processes, composite heating technologies, and composite part build methodologies.


AFP Robot Cell - Various R&D

EI Accurate Robot motion platform with 30m X-axis. Originally built for rocket part production, now primarily used for R&D and single build, demonstrator parts.

  • Multiple 1/4"
  • 1/2" 16 tow AFP
  • Probe
  • Very large horizontal rotator (100k lbs, 20ft+ diam. Parts)
  • Integrated elevating platform for operator part access
  • Integrated laser projection

Dual Zone AFP Robot Cell - Rocket Structures

EI Accurate Robot motion platform with 12m X-axis. Dual zone operation with small round parts and larger fixed parts on one side, integrated vacuum table on other side.

  • 1/4" 16 tow AFP
  • Probe with ultrasonic cutting
  • Small horizontal rotator (100k lbs, 20ft+ diam. Parts)
  • Integrated vacuum table (20'x6')
  • Ultrasonic cutting capability

Dual AFP Robot Cell - Flat Charges for Fuselage Frames

Dual EI Accurate Robot motion platforms with 18m X-axes. Each robot is paired with a large vacuum table for layup of preform flat charges. Each vacuum table is fitted with a 4 axis ultrasonic cutting gantry for part trimming.

  • Multiple 1/4" 16 tow AFP
  • Probe
  • Large vacuum table (50'x8') with integrated control and individual vacuum zoning
  • 4 axis ultrasonic cutting gantry with part marking capability

High Rail Gantry - Various Production + R&D

High rail 7 axis gantry with linear motors on all linear axes, 27m X travel. The gantry is paired with a medium capacity rotator with removable tail stock to retain full cell utilization. Laser projection is integrated into the machine platform.

  • 2 x 1/2" 16 tow AFP heads
  • 1 x 1/4" 8 tow AFP head
  • 1 x 1/2" 16 tow head is configured to process Tungsten-Boron material

Fuselage Post Machines - Wide Body Commercial Aircraft Fuselage Forward Section

Two fuselage lamination cells, each with a pair of giant 6-axis post machines concurrently laminating on a high-performance rotator. These machines lay 1/2" and 1/4" prepreg


High Rail Gantry - Various R&D

A 7-axis, high-rail gantry machine with an infinite C-prime axis, for a Boeing R&D cell.

  • 16-lane 1/2" head (H16)
  • 8-lane 1.5" head (OH8)
  • Ultrasonic knife head

Fuselage Gantry - Wide Body Fuselage Sections

Four lamination cells each with a 6-Axis vertical ram style gantry machines with an unlimited C-axis. Each system is provided with two modular 16-lane 1/2" heads (H16) for laying up prepreg material. Laser projection is integrated into the machine cell foundation.

  • Machines 2 through 4 have an ultrasonic knife capabilities
  • Modular Vacuum Table (68' x 5')

AFP Robot - Rocket Sections

2 Electroimpact accurate robots, 3 high capacity rotator stations, 2 x 1/2" heads, 1 x 1/4" head and 2 inspection platforms.