BCI Showcases Research at ECCM21

In previous years, the European Conference on Composite Materials has been at the forefront of showcasing innovation and key research developments into composites: ECCM21 (July 2024) was no different, with over 25 presenters from Bristol Composites Institute alone! A full list of presentation titles and abstracts can be found here on our blog.

Hosted in the city of Nantes, France, an impressive variety of topics ranging from structural performance and material fundamentals all the way up to large-scale industrial process and simulation were on offer. Comprising of a mix of introductory tutorials, posters and parallel presentation sessions, the conference delivered on providing insight and highlighted trends towards more sustainable use of composites – an ever-growing topic of importance in today’s world.

Of particular note in this conference was the focus on machine learning and data-driven approaches to composites: for example, to advance current simulation and process modelling of liquid composite moulding, to in-line monitoring during deposition using novel sensors and inspection techniques. Data is fast-becoming an increasingly valuable asset used by manufacturers and customers, particularly in the aerospace sector, to make more informed decision-making about how to best navigate the challenges in a post-pandemic global supply chain.

However, the ways in which data is processed is just as important, but can be expectedly variable given the diversity and spread of the composites community. Take the microstructure of a composite laminate, typically, a micrograph of the laminate cross-section is captured and the fibre volume fraction quantified using image-analysis.
The challenge? Methods X, Y & Z used to analyse the same image all return different values. The first step towards a solution? An image-based benchmark to establish guidelines for improving the consistency between researchers and therefore, increasing confidence in their analyses and maturation for industrial applications.

It is clear that composites has a far-reaching impact on many sectors and research themes. To capitalise on these innovations, the continued active dialogue between industrial and academic partners is of critical importance.

written by Umeir Khan, PhD Aerospace Engineering.

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NextCOMP enjoyed a very successful set of 5 special sessions at ECCM21 which took place across two days on the subject of “Understanding and Improving longitudinal Compressive strength”.  With a keynote from Prof Michael Wisnom a highlight, the sessions which took place in a large auditorium at le Cite Congres, Nantes were very well attended and sparked considerable interest, conversations and discussions in and outside the sessions.  Speaker contributions from academia and industry meant the sessions successfully showcased the excellent research into composite compression being undertaken around the world. Once again, this focussed session has facilitated the creation of new connections and collaborations to extend the NextCOMP Programme’s research in the future.

The NextCOMP team from BCI and Imperial College enjoyed a very productive week at the conference, and were pleased to attend numerous fascinating talks on a range of different subjects including the latest composites research.  After-hours highlights in the lovely city of Nantes included many crepes, visits to fascinating historical buildings and some unique street and creative arts spaces – certain members of the NextCOMP team might have even been spotted watching some entertaining Euro football matches (with colleagues and friends from around the world).  We thank the organisers for a fantastic conference, which we all thoroughly enjoyed!

written by Jo Gildersleve, NextCOMP Project Manager.

Festival of Enterprise returns for third year

Our Early Career Enterprise Fellows, James Uzzell and James Griffith were fine ambassadors for BCI at the 2024 Festival of Enterprise. Both delivered excellent presentations with aplomb to an expert panel of judges and answered questions on their work.

Judging was extremely tight and both were highly commended; James Griffith being a narrow second in the panel judgement but won the audience vote and prize for the most engaging presentation titled “Developing Composite Solutions for Cryogenic Liquid Hydrogen Fuel Storage on Zero Carbon Emission Aviation (Developing Materials for Net-Zero Flight).”

James Uzzell’s presentation was focused on dynamic induction coils for energy efficient composites manufacturing.

The event, which was held in the Bill Brown Design Suite within the Faculty of Engineering on Thursday 20 June, focused on showcasing the range of research and enterprise activities, the people that have been supported and the impact of the funding and training provided by the University Enterprise Fellowships (UEFs) and Early Career Enterprise Fellowships (ECEFs).

The event featured presentations by the 23/24 Cohort of UEFs, and a series of PechaKucha style presentations by our ECEFs with an expert panel of judges who awarded the prize for best presentation with regards to project outcome & impact, in addition to an audience vote and prize for the most engaging presentation on the day.

Bristol spinout raises more than £17.5m to deliver cutting-edge composites

University of Bristol spinout company iCOMAT has secured more than £17.5m in funding to deliver lighter transport solutions faster and at a lower cost.

iCOMAT is one of the leading manufacturers of advanced composite structures for the aerospace and automotive industries Image credit: iCOMAT

Founded by Dr Evangelos Zympeloudis, iCOMAT is one of the leading manufacturers of advanced composite structures for the aerospace and automotive industries.

iCOMAT’s Rapid Tow Shearing (RTS) process means carbon fibre tapes can be used in physically curved positions without being damaged or becoming defective.

Unlike traditional methods which create components by layering straight fibre layers, iCOMAT’s solution allows for the fibres to be directed precisely, optimising the structural property at any given point. The technology can significantly reduce weight compared to existing commercial solutions, and considerably improve production rates.

The investment round was led by 8VC, a technology and bio-sciences venture capitalist firm, alongside the NATO Innovation Fund. Other investor partners include Syensgo Ventures and existing iCOMAT investors Velocity Partners VC.

The Bristol-based company has had a long affiliation with SETsquared and its academic partners at the University of Bristol.

iCOMAT is currently working with more than 25 customers from across the aerospace, defence and automotive sectors, and has successfully delivered parts for demanding applications including fighter aircraft panels, space launcher structures, and Formula 1 components.

To meet demand, iCOMAT is in the process of building its first production factory in Gloucester. The state-of-the-art facility will house three RTS production lines, alongside an array of other advanced processing equipment. It is anticipated that the factory will be fully operational by the end of 2024.

iCOMAT founder and CEO, Dr Evangelos Zympeloudis, said: “Our RTS process not only offers unparalleled structural efficiency, but unlocks fully automated production workflows.

“We are thrilled to partner with our investors and accelerate progress toward our mission – to revolutionise transportation by delivering the lightest structures and vehicles possible.”

Bristol scientists to participate in £42.5M national Centre of Excellence in advanced materials

The University of Bristol and its Bristol Composites Institute is part of a new Defence Science and Technology Laboratory (Dstl) funded £42.5M partnership with academia, industry and RTOs to deliver ground-breaking new research into materials for extreme environments.

 

Advanced materials play a vital role in keeping people and equipment safe in the harsh physical environments such as polar or tropical heat, shock, space and extreme water depth. The new Defence Materials Centre of Excellence (DMEx) will be led by the Henry Royce Institute along with 23 other partners from academic, industry and research organisations. Using leading edge technology, the Bristol Composites Institute, along with other researchers across the Science and Engineering Faculty will contribute to this national effort in advanced materials research.

 

Regius Professor Phil Withers FRENg FRS, Chief Scientist at the Henry Royce Institute and Regius Professor at the University of Manchester, said: “I am very excited about this opportunity for the Royce to team up with Catapults, industry, other universities and Dstl to bring many of the brightest minds and state of the art capabilities together to undertake materials research and development in support of the UK.”

 

Stephen Hallett, who led the University of Bristol’s participation in the bid and will represent the Air Domain as Partner Principle on the DMEx Science Board said: “It is great to be part of this successful consortium, that will allow Bristol researchers to contribute their expertise and skills.

 

As the DMEx centre gets underway and gathers momentum, research at Bristol will support the upscaling of exciting new materials and technology and feed into the growth of advanced materials activity, which is estimated at £14.4 billion in gross value to the UK economy.

 

Written by Simon Quinn, BCI Engagement Manager.

Net Zero Challenges Policy Project

The Bristol Composites Institute (BCI) has recently welcomed Dr Jack Dury, a Civil Service Fast Streamer, on a 6 month secondment to identify how academia, the National Composites Centre (NNC) and industry can best influence and inform future policy making and practice so that composite materials are utilised to their full potential to meet the global challenge of Net Zero.

The work will identify policy blockers, workshop solutions through engagement with the composites community, and summarise findings in a white paper. The white paper will make the case for composites, describe the policy blockers and how Governments can support the composites industry, in addition to what the future regulatory landscape will look like and potential solutions.

To support the work, please complete this survey on your experiences of the industrial use of composite materials and government policy. The findings will be disseminated widely in autumn 2024.

For further information, or to engage with the work, please contact jack.dury@bristol.ac.uk.

BCI have been awarded funding from EPSRC and 29 industrial partners of £20M for 6th Centre for Doctoral Training

Following our successful application to EPSRC led by Professor Janice Barton for our sixth Centre for Doctoral Training, we are delighted to announce we will be able to train 67 doctoral students over five years starting in 2024.

The EPSRC Centre for Doctoral Training (CDT) in Innovation for Sustainable Composites Engineering will train highly skilled future leaders equipped with the expertise and resilience to address the sustainable design, manufacture, and assurance of composite products. 

The focus of the Centre differs considerably to the previous ones with sustainability as a continuous thread and close interaction with industry, with research projects running across the four years of the programme. An entirely new taught programme has been designed, which aligns with structured professional development activities that focusing on creating the leaders of tomorrow.  

Dr Lee Harper from the University of Nottingham presents the key points of the research programme

The research projects will provide a means of achieving environmental neutrality for composite products through production, service, and reuse. The research topics include the pursuit of more sustainable composite materials, creation of energy efficient manufacturing processes and novel data-driven design approaches that take advantage of the freedoms offered by composite materials to generate efficient structural concepts.
The target is to create inherently sustainable composite solutions, able to perform in diverse environments, and made using new scientific advances, with new energy efficient, waste-free manufacturing procedures.
 

Attendees were encouraged to discuss thoughts and ideas in the afternoon break-out session

We recently hosted a CDT in Innovation for Sustainable Composites Engineering Start-up meeting with Industrial Partners at the University of Bristol, which created an opportunity for researchers and industry experts to discuss the key targets of the centre and how these will be achieved. It was a successful day with a space for thoughtful conversation welcomed in the break-out group session.
The event targeted the setting up of new research projects with common goals identified such as low-cost tooling to enable high-rate manufacture, in-process NDT, new approaches to acceptance and certification and development of a life cycle assessment tools. Professor Janice Barton remarked “I am pleased that so many of our industrial partners were able to attend and help shape the start of the CDT. The engagement across academia and industry is key to the success of all aspects of the CDT.”

The CDT is strongly supported by the UK composites sector and is a partnership with University of Nottingham, the National Composites Centre, National Physical Laboratory, Henry Royce Institute, and 26 industrial partners representing a diverse range of sectors: Aerospace (Airbus, Rolls-Royce, Dowty, Leonardo, GKN), Defence (QinetiQ, AWE, BAE Systems), Automotive (Gordon Murray, JLR), Wind Energy (Vestas, EDF-Renewables), Marine (Tods), Rail (Network Rail), Oil and Gas (Magma Global), Hydrogen (Luxfer), Material suppliers (Hexcel, Syensco, iCOMAT, SHD), Design and manufacturing companies (Pentaxia, Actuation Lab, LMAT, Carbon ThreeSixty), RTOs (NPL, NCC, Royce, HVMC).  

The list is not exclusive; we welcome participation from other companies. If you would like to be involved, please contact composites-institute@bristol.ac.uk  

 

BCI Alumni Q&A: Reece Lincoln

As part of our Alumni Series, we speak to Reece Lincoln, Senior Engineer at Frazer-Nash Consultancy about life after the BCI…

Why did you choose the Bristol Composites Institute for your studies?
I chose the Bristol Composites Institute as it is a world-class research institute for composites. I was interested in researching composite structures and there was no better place to go. I was attracted to the PhD programme as it was cohort-based, meaning it wouldn’t be a completely solo adventure. I was also at Bristol Uni for my undergrad, so I knew the lecturers and research staff were excellent. 

What research area did you specialise in whilst you were here?
I specialised in structures, specifically shell buckling. I researched how a BCI-created manufacturing technique, Rapid Tow Shearing, could be used to reduce the sensitivity of thin-walled shells to premature buckling under axial compression. I showed that with Rapid Tow Shearing, a more mass-efficient structure could be manufactured, which could lead to direct mass savings on a structure. 

 

After leaving the BCI where did you go?
I have been working at Frazer-Nash Consultancy for the past 15 months, working on data science and machine learning projects. 

What are you currently working on and what do your future plans look like?
My projects are wide ranging – but general process is similar – I work in a team of two to five that creates a model of a complex system. We then visualise this model in an interactive tool for the client. I have worked on modelling the graphite within nuclear reactors, the roll-out of gigabit-capable internet across the UK, the cost and performance of a space-based solar-power satellite, the resilience of the UK energy network to weather events, and the post-processing of nuclear waste. My future plans are to continue what I’m doing now – working on tough problems that are impactful and interesting. 

How did the BCI prepare you for work outside of academia?
BCI prepared me for work outside academia by teaching me how to be rigorous in understanding a problem, methodical in my approach to creating a solution, and critical of the results any solution produces. BCI also taught me how to communicate clearly and concisely, recognising that technical problems have ‘stories’ to tell and the story is as important as the solution. 

BCI Alumni Q&A: Riccardo Manno

As part of our Alumni Series, we speak to Riccardo Manno, Research and Development Engineer at Ansys about life after the BCI…

Why did you choose the Bristol Composites Institute for your studies?
Back in 2017 I was involved in a research project that saw me spending some time in an University in US. That time I realized I wanted to pursue a PhD in some relevant University. I therefore, started searching for the best academic institutes around the world and I came across BCI. Looking at the website I suddenly understood that it was the place to be for an Advanced Composites Doctorate. 

What research area did you specialise in whilst you were here?
I was mainly involved in the numerical modelling of advanced Ceramic Matrix Composites within the Rolls Royce University of Technology Centre at BCI. I also had the opportunity to collaborate with engineers working at Rolls Royce as well as other researchers based at Imperial College London and University of Oxford. I have to say it was an incredible journey. 

After leaving the BCI where did you go?
After finishing my PhD I won a Knowledge Transfer Secondment of which I was the Principal Investigator. During this time, I transferred all the work that I had produced during my PhD to Rolls Royce. While, completing the file period of the KTS I secured a position at Ansys as Research and Development Engineer. 

What are you currently working on and what do your future plans look like?
In my day to day, I implement models and pieces of software which are used for performing multiscale simulations of composite and lattice materials. I am happy to work at Ansys and I am trying to build as much knowledge as possible for progress within the company. 

 How did the BCI prepare you for work outside of academia?
I think BCI is an excellent starting point for working within academia as well as outside academia. It is really well known around the world from companies working in the composites field. Furthermore, all the trainings provided by the BCI prepared me well to make the leap into industry after my PhD and Postdoc. 

Bristol Composites Institute at ECCM21

We are pleased to announce an impressive line up of academics, researchers and PhD students from the Bristol Composites Institute (BCI) who will be presenting their latest work at ECCM21 (the 21st European Conference on Composite Materials) in Nantes, France, from 2nd-5th July 2024.

 

ECCM is Europe’s leading conference on composite materials and will provide a forum for access to the latest knowledge from both industry and academia in all areas of composite materials. The event is organised by the Institute of Civil Engineering and Mechanics (GeM) of the Nantes Université and Centrale Nantes, under the patronage of the European Society for Composite Materials (ESCM) and the French Association for Composite Materials (AMAC).

The NextCOMP team will be hosting sessions on “Understanding and improving longitudinal compressive strength”. These will be taking place in Auditorium 450 on Wednesday 3rd July, 14:30-16:00, and all day on Thursday 4th July, including a keynote from Prof. Michael Wisnom at 14:00 on the Thursday.

Wednesday 3 July BCI speaker line-up:

Room BC / 09:30 – speaker: Ole THOMSEN. Title: Co-Director Bristol Composites Institute.  Talk title: Integrated testing and modelling of composite structures – a journey towards virtual testing and certification by analysis. Abstract.

Room BC / 10:15 – speaker: Meng Yi SONG. Title: Research Associate. Talk title: Application of second-order multi-scale modelling to composite components with delamination, fibre and matrix damage. Abstract.

Room I / 10:15 – speaker: Umeir KHAN. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Talk title: Quantifying preform quality through defect inspection of in-factory photographs. Abstract.

Room BC / 10:30 – speaker: James KRATZ. Title: Senior Lecturer, School of Civil, Aerospace and Design Engineering. Talk title: Characterization of micro-structural features in complex parts for use in digital technologies. Abstract.

Room 200 / 11:30 – speaker Hengli CAO. Title: Postgraduate. Talk title: Metal-epoxy-matrix carbon-fibre hybrids for functional and structural applications. Abstract.

Room I / 12:00 – speaker: Gabriel BURKE. Title: Faculty Intern, School of Civil, Aerospace and Design Engineering. Talk title: Artificial Intelligence for Process Monitoring of Automated Fibre Placement – Real-time Defect Detection and Classification. Abstract.

Auditorium 450 / 14:30 – speaker: Iheoma NWUZOR. Title: Research Associate. Talk title: Integrating Fiber Overbraids in Composites for Enhanced Compressive Performance. Abstract.

Room KL / 14:45 – speaker: James UZZELL. Title: Postgraduate, Advanced Composites. Talk title: New inductive coil designs for improved efficiency in composites processing. Abstract.

Room 150 / 14:45 – speaker: Dominic PALUBISKI. Title: Senior Research Associate. Talk title: Liquid Moulding Strategies for Challenging Functional Matrices: Repair and Energy Storage Applications. Abstract.

Auditorium 450 / 15:30 – speaker: Ian LEE. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Talk title: Cobotic manufacture of hierarchically architectured composite materials. Abstract.

Poster Presentations:

Mezzanine, 16:00 – 17:30

Maria VEYRAT CRUZ-GUZMAN. Title: Graduate Teacher, School of Chemistry. Poster title: Crystallisation Kinetics of PEEK Composites using Fractional Differential Equations.

Sutharsanan NAVARATNARAJAH. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Poster title: A Curved-Crease Origami Approach to Forming Composite Structures

Thursday 4 July BCI line-up:

Club Atlantique / 09:15 – speaker: Bing ZHANG. Title: Visiting Research Fellow, School of Civil, Aerospace and Design Engineering. Talk title: A numerical investigation into the electrical properties of through-thickness reinforced composites. Abstract.

Auditorium 450 / 09:45 – speaker: Joe RIFAI. Title: Postgraduate, Advanced Composites. Talk title: The effects of stacking sequence on the compressive performance of composites. Abstract.

Club Atlantique / 10:00 – speaker: Christian STEWART. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Talk title: Damage Tolerance of 3D Woven Composites. Abstract.

Auditorium 450 / 10:30 – speaker: Eleni GEORGIOU. Title: Postgraduate, Advanced Composites. Talk title: Enhancing the compressive performance of basalt/epoxy pultruded rods using polyhedral oligomeric silsesquioxane (poss) as nano- reinforcement. Abstract.

Room R02 / 11:15 – speaker: Ogun YAVUZ. Title: Senior Resident. Talk title: Isothermal forming simulation of HiPerDiF PLA/Carbon fibre layer under processing conditions. Abstract.

Auditorium 450 / 11:30 – speaker: Nicolas DARRAS. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Talk title: Investigation of the internal structure configuration of hierarchical composites and its impact on their mechanical compressive performances. Abstract.

Club Atlantique / 11:45 – speaker: Athira Anil KUMAR. Title: Graduate Teacher. Talk title: Implementation of Second-Order Homogenisation using Shell Elements for Woven Composites. Abstract.

Room 200 / 12:00 – speaker: Anatoly KOPTELOV. Title: Senior Research Associate. Talk title: A rapid Design for Manufacturing tool for injection over-moulded composite parts​. Abstract.

Room KL / 12:15 – speaker: Prof. Janice DULIEU-BARTON. Title: Professor, School of Civil, Aerospace and Design Engineering. Talk title: Embedded flexible photonic sensors for cure monitoring and assessment of structural performance. Abstract.

Auditorium 450 / 14:00 – speaker: Prof. Michael WISNOM. Title: Professor of Aerospace Structures. Talk title: Compressive failure of carbon fibre composites due to instability at structural, material and constituent level. Abstract.

Auditorium 450 / 14:30 – speaker: Bohao ZHANG. Title: Research Associate. Talk title: The investigation of shear response of epoxy matrix under uniform compression. Abstract.

Auditorium 450 / 14:45 – speaker: Cameron WOODGATE. Title: Laboratory Assistant, School of Civil, Aerospace and Design Engineering. Talk title: Probing Compressive Behaviour and Failure in Single Carbon Fibre Composites: an In-depth Analysis using in-situ Laser Raman Spectroscopy. Abstract.

Room 200 / 14:45 – speaker: Jack DAVIES. Title: Postgraduate, Composites Manufacture. Talk title: A Numerical Tool for Smart In-situ Sensing of Defect Features in Large-scale Infusions. Abstract.

Room BC / 15:30 – speaker: Kyungil KONG. Title: Senior Research Associate. Talk title: Hydrodynamic Stable Suspension of Recycled Carbon Fibres through Eco-friendly and Cost-effective Surface Treatment. Abstract.

Room 200 / 15:30 – speaker: Hanna BEKETOVA. Title: Research Associate. Talk title: Prepreg consolidation predictions using deep learning. Abstract.

Auditorium 450 / 15:30 – speaker: Aree TONGLOET. Title: Graduate Teacher, School of Civil, Aerospace and Design Engineering. Talk title: Effect of hybridisation on the compressive behaviour of glass/carbon fibre hybrid composites comprising different types of carbon fibres. Abstract.

Auditorium 450 / 17:30 – speaker: Dr. Laura Rhian PICKARD. Title: Senior Research Associate. Talk title: Fuzzy overbraids for improved structural performance. Abstract.

Research-based Automated Deposition: A new material characterisation and process development tool

By Ege Arabul, Dr James Kratz & Dr Vincent K. Maes

Summary 

A new research tool has been developed and commissioned at the University of Bristol, see Figure 1, to investigate the Automated Fibre Placement (AFP) deposition process. The machine, named “Real-Time AFP”, allows for composite pre-preg tape to be delivered onto a surface in an AFP/ATL-representative manner, where the process parameters, such as compaction force, temperature, speed and tow tension, can be varied, and the material tack can be characterised. The device also monitors the deposited tape and captures data in real time, allowing for the detection of manufacturing defects and correlation to the process parameters. The device aims to accelerate research into a wide range of AFP related topics, including novel sensor development, real-time control algorithms, and dedicated material benchmarking standard for AFP processes. 

 

Figure 1The newly commissioned Real-Time Automated Fibre Placement (RT-AFP) Machine in the Bristol Composites Lab (BCI). 

 

Introduction

Automated Fibre Placement is a technique to deliver semi-finished, composite pre-preg tape onto a surface where narrow pre-preg slices are collimated on the head and delivered together through the use of a gantry head, heater, and a compaction roller. This technique is particularly well suited for gently curved or larger structures where a robust and repeatable manufacturing technique is needed, such as in aerospace applications, and where variable stiffness composites are needed such as in hyperbolic blended wing bodies, c-spars, and engine fan blades, which can be achieved through tow steering.

While automation of composite manufacturing processes has been successfully industrialised, part inspection and re-work remains a manual process, which can take up to 42% of the total time per build (Rudberg, T, “A Process for Delivering Extreme AFP Head Reliability”, 2019). Furthermore, this inspection is usually conducted only visually, which is highly dependent on the skill of the technician. Supplemented by the increasing trends in Industry 4.0 and a global emphasis on sustainability aimed to reduce waste and increase efficiency in composite manufacturing, methods to detect and react to defects during manufacturing are of great industrial interest.

 

The Key Features and Capabilities of RT-AFP

The in-house “RT-AFP” rig was developed to address the gap between the AFP representative lab experiments and the full-scale AFP deposition using a commercial AFP machine, which has varying degrees of process complexity, as shown in Figure 2. A key consideration in developing this machine was to ensure it provided rich, in-process deposition data, which many commercial AFP solutions would not offer for research purposes.

The key features of this machine include;

  • Closed-loop control over AFP parameters, such as the layup temperature, compaction force, speed and tow tension.
  • A real-time data capture system, including laser scanner profilometry data, to monitor the deposition process.
  • Material tack characterisation capability via peel-tack-testing after deposition.
  • Implementation of novel sensors in a modular manner.
  • Ability to vary process parameters on the fly and implement different setpoint profiles.

 

Figure 2- Varying degrees of complexity in AFP research, with RT-AFP being in the middle.

 

Figure 3 illustrates the key components of the machine and its operating principles. The image on the left-hand side shows the loading of the composite pre-preg tape as it is being deposited. The pre-deposition and post-deposition laser scanners scan prior to and after the tape deposition, respectively, and can be used to subtract data from one another to identify the incoming tape and any misalignment or defects on the tape. After the deposition, the deposited tape can be peeled off by running the machine reverse.

Figure 3-The key components of the RT-AFP

 

Success Stories and Future Outlook

The “RT-AFP” has already been a critical resource for researchers investigating the AFP process. Some highlight studies include a comparison between the AFP and hot press processes for a layer-by-layer curing technology[1], a real-time defect detection system using laser scanners with convolutional neural networks to classify different types of deposition defects [2] and a real-time process control algorithm to mitigate influence of certain defects during deposition [3].

With strong ties to sensor development teams within the university, including non-destructive testing and evaluation, the “RT-AFP” is a growing tool to accelerate research. Along with these studies, the device is also being used to correlate the process parameters to the evolution of AFP manufacturing defects to better inform our understanding, and models of the AFP deposition process and to develop novel techniques to eliminate arising defects on the fly. The research team invites future collaborators investigating the AFP process, within and external to the university, to utilise the machine to accelerate their research capabilities.

 

Figure 4-Summary of key success stories using the RT-AFP

 

Linked Articles:

  1. Hartley, R., & Kratz, J. (2024). CFRP layer-by-layer curing using research-based automated deposition system. Manufacturing Letters, 40, 85–88. https://doi.org/10.1016/j.mfglet.2024.03.005
  2. https://composites.blogs.bristol.ac.uk/2023/11/30/real-time-quality-control-in-automated-fibre-placement-using-artificial-intelligence/
  3. Nguyen, D. H., Sun, X., Tretiak, I., Valverde, M. A., & Kratz, J. (2023). Automatic process control of an automated fibre placement machine. Composites Part A: Applied Science and Manufacturing, 168, 107465. https://doi.org/10.1016/J.COMPOSITESA.2023.107465