Systems and methods to automate composite manufacturing quality checks

A method of determining an integrity of a composite article comprising:

• measuring, by a sensor system, a first characteristic corresponding to the integrity of the composite article during layup of the composite article;
• identifying a defect present in the composite article after curing by analyzing the defect vis-à-vis a database of historical data using one or more machine-learning techniques;
• measuring, by the sensor system, a second characteristic corresponding to the integrity of the composite article after curing the composite article;
• analyzing, at a core platform, the first characteristic and the second characteristic vis-à-vis the database;
• determining whether the identified defect is present in the composite article after curing;
• and
• generating an alert in response to a determination that the defect exists in the composite article based on the first measurement or the second characteristic.

An automated inspection system for monitoring integrity of a composite article during different stages of a manufacturing process, the automated inspection system comprising:

• an actuation system configured to adjust one or more parameters of the manufacturing process;
• a sensor system configured to monitor one or more characteristics corresponding to an integrity of the composite article during the manufacturing process, wherein the sensor system comprise a non-contact ultrasound to capture the first characteristic;
• and
• a processor operatively coupled to each of the actuation system and the sensor system, wherein the processor is configured to:
• determine, via the sensor system, a first characteristic corresponding to the integrity of the composite article during layup of the composite article;
• identify, via a processor, whether a defect is present in the composite article after curing by analyzing the first characteristic vis-à-vis a database of historical data using one or more machine-learning techniques;
• adjust, via the actuation system, one or more parameters of the manufacturing process to mitigate manifestation of the defect;
• measure, by the sensor system, a second characteristic corresponding to the integrity of the composite article after curing the composite article;
• determine, via the processor, whether the defect is present in the composite article after curing the composite article;
• and
• generate, via the processor, an alert if the defect is present.