Automated fiber-placement systems and methods

An automated fiber-placement system, comprising:

• a dispenser, configured to dispense at least one fiber-reinforced tape strip, and wherein:
• at least the one fiber-reinforced tape strip comprises a first longitudinal tape-edge and a second longitudinal tape-edge, parallel to the first longitudinal tape-edge and spaced from the first longitudinal tape-edge by a tape-strip width;
• and
• at least the one fiber-reinforced tape strip comprises a resin tape-matrix and unidirectional reinforcement fibers, imbedded in the resin tape-matrix;
• a compactor, configured to receive at least the one fiber-reinforced tape strip from a leading side of the compactor and to compact at least the one fiber-reinforced tape strip against a substrate;
• a steering mechanism, configured to manipulate the dispenser and the compactor in at least one of two- or three-dimensional space relative to the substrate;
• an energy source, configured to deliver a first quantity of pulsed energy and a second quantity of pulsed energy to the leading side of the compactor for respectively heating, to a first temperature, first discrete portions of at least the one fiber-reinforced tape strip and, to a second temperature, second discrete portions of at least the one fiber-reinforced tape strip, alternating with the first discrete portions along at least the one fiber-reinforced tape strip;
• and
• a controller, programmed to control at least one of feed rate of the at least the one fiber-reinforced tape strip from the dispenser or pulse frequency, pulse power, or pulse duration of at least one of the first quantity of pulsed energy or the second quantity of pulsed energy and also programmed to selectively cause the steering mechanism to place at least the one fiber-reinforced tape strip against the substrate at least along a virtual curvilinear path, such that:
• at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path;
• and
• the first discrete portions of at least the one fiber-reinforced tape strip are transformed into discrete tape-regions, geometrically different from the first discrete portions.