Hybrid formation of multi-layer prepreg composite sheet layup

A method for automating prepreg sheet layup within a workspace to form a three-dimensional (3D) part by a robotic system comprising:

• prior to entering a dataset via a user input to a processor disposed of in the robotic system, selecting by at least one user, a mold design and material selection by enabling the at least one user to review draping simulations to sheet geometries for draping and conduct manual trials to record start and end point pairs for a layup sequence into the dataset wherein the dataset is stored in the memory;
• communicating by the processor to the memory for retrieving the dataset stored in the memory that includes the start and end point pairs of a mold of the 3D part that is associated with the mold design selected by at least one user;
• generating, by the processor, a layup sequence based on the dataset;
• generating, by the processor, a plurality of trajectories for one or more movements of a first robot or a first robot arm based on the layup sequence;
• causing, by the processor, a second robot or a second robot arm to hold or grasp the prepreg layer or sheet a threshold distance above the mold of the 3D part;
• and
• causing, by the processor, the first robot or the first robot arm to place or conform the prepreg layer or sheet to the mold of the 3D part.