High rate production fiber placement system and method

A fiber placement system comprising:

• a first fiber placement station at a first location, said first fiber placement station comprising:
• a first tool;
• and
• a first fiber placement assembly configured to construct a first reinforcement layup on said first tool, said first reinforcement layup comprising a thermoplastic matrix material, said first fiber placement assembly comprising:
• a first compaction roller rotatable about a first axis of rotation, said first compaction roller at least partially defining a first nip;
• and
• a first laser positioned to supply heat proximate said first nip;
• a second fiber placement station at a second location, said second fiber placement station comprising:
• a second tool;
• and
• a second fiber placement assembly configured to construct a second reinforcement layup on said second tool, said second reinforcement layup comprising a thermoplastic matrix material, said second fiber placement assembly comprising:
• a second compaction roller rotatable about a second axis of rotation, said second compaction roller at least partially defining a second nip;
• and
• a second laser positioned to supply heat proximate said second nip;
• a consolidation station at a consolidation location, said consolidation location being different from said first location and said second location, said consolidation station comprising:
• a consolidation tool;
• and
• a consolidation system configured to consolidate a reinforcement layup assembly comprising said first reinforcement layup and said second reinforcement layup;
• and
• a first transfer apparatus positioned to move said first reinforcement layup from said first tool to said consolidation tool.

A fiber placement system comprising:

• a first fiber placement station at a first location, said first fiber placement station comprising:
• a first tool;
• a first fiber placement assembly configured to construct a first reinforcement layup on said first tool, said first fiber placement assembly comprising a compaction roller rotatable about an axis of rotation, said compaction roller at least partially defining a nip;
• a consolidation station at a consolidation location, said consolidation location being different from said first location, said consolidation station comprising:
• a consolidation tool;
• and
• a consolidation system configured to consolidate a reinforcement layup assembly comprising said first reinforcement layup and at least one more reinforcement layup;
• and
• a transfer apparatus positioned to move said first reinforcement layup from said first tool to said consolidation tool.