Scarf repair apparatus, system, and method

A system for forming a first void in a laminated material of a part to repair the part, the system comprising:

• a scarf repair guide, comprising a physical guide based on a digital scarf repair model, non-movably fixed relative to the part and comprising a second void, wherein the first void matches the second void;
• and
• an arm assembly, comprising:
• an arm, comprising a first end portion and a second end portion, wherein the first end portion is spaced apart from the second end portion;
• a probe, fixed to the first end portion of the arm and configured to trace the second void in the scarf repair guide;
• and
• a milling tool, fixed to the second end portion of the arm such that the milling tool is co-movably coupled with the probe via the arm, wherein the milling tool is configured to form the first void in the part to match the second void in the scarf repair guide as the probe traces the second void in the scarf repair guide.

A method of making a scarf repair guide for repairing a laminated material of a part, the method comprising:

• scanning at least a portion of the part containing an abnormality;
• generating data corresponding with the abnormality in response to scanning at least the portion of the part containing the abnormality;
• generating a digital scarf repair model based at least partially on the data corresponding with the abnormality;
• and
• making the scarf repair guide, comprising a physical guide, based on the digital scarf repair model.

A method of repairing a laminated material of a part, the method comprising:

• tracing a second void, of a scarf repair guide non-movably fixed relative to the part, with a probe, wherein the scarf repair guide is based on a digital scarf repair model generated by a scarf repair modeling module configured to generate the digital scarf repair model based at least partially on data corresponding with an abnormality in the part;
• co-moving a milling tool with the probe as the probe traces the second void;
• and
• removing the laminated material of the part with the milling tool as the milling tool co-moves with the probe to form a first void in the laminated material of the part that matches the second void in the scarf repair guide.