Composites automation beyond AFP limits: Mastering steep-edge lay-up with Fiber Patch Placement

To showcase the advanced lay-up capabilities of Fiber Patch Placement (FPP) technology, Cevotec has developed a new demonstrator that exemplifies a typical “impossible-to-overcome” challenge for automated fiber placement.

Composites automation beyond AFP limits: Lay-up over steep edges with FPP

The lay-up challenge: Double-curved barrel section

The demonstrator replicates a double-curved section of a barrel with a 2-meter diameter. The mold, measuring 500 x 200 mm, includes an 80° stepped feature with a 40 mm height—simulating the outer skin of a typical sandwich core structure such as those found in storage tanks, engine nacelles, or secondary fuselage components.

High-quality lay-up through Post-Placement Push-In

Using the new Post-Placement Push-In feature, the placement gripper on Cevotec’s SAMBA Pro system drapes the patches precisely around the edge and onto the curved surface. This ensures a uniform laminate quality with high compaction even over tight geometries.

Process details

• Lay-up configuration: [0°, -45°, +45°]S
• Material: 50 mm-wide UD prepreg, 150 gsm
• Mold: 3D-printed tooling
• Lay-up system: Cevotec SAMBA Pro PV Lab

This lay-up demonstration reaffirms FPP’s strength in producing high-performance composites with precise fiber orientation and excellent conformity to complex geometries. Manufacturers of high-performance composite can finally bridge the automation gap between traditional AFP and manual lay-up.