Real-time Automated Ply Inspection (RTAPI) is a layup inspection system that determines if the layup produced by an Automated Fiber Placement (AFP) machine meets drawing requirements. This is performed in real-time, while the machine is laying composite tapes onto the mold at very high speed, providing several benefits. As a fully automated system it eliminates very slow and tedious manual inspection performed currently. RTAPI provides greatly reduced cycle and improved productivity by eliminating the secondary inspection step (when the machine is idle). It also creates a digital record (thread) how the part was made, which doesnt exist today. Flightware will leverage earlier work to develop an Automated Ply Inspection (API) system, which automated AFP layup inspection using a laser sensor, robot and software, some of which are common to RTAPI. Yet API is still a secondary, series step. For RTAPI, we focus on several challenges performing very fast, real-time operation with an AFP head-mounted sensor. Flightware is teamed with Fives, a leading supplier of large AFP equipment, to demonstrate RTAPI on a Viper machine. In addition Hitco, one of two F35 primary AFP parts suppliers, has expressed strong interest in using the technology in Phase II.
