Automated placement of composite material

A method for automated placement of composite material on a surface for manufacturing a component, the composite material including unidirectional fibers, the method comprising:

• establishing an initial set of fiber paths along the surface, the initial set of fiber paths comprising at least one ply, each ply comprising a respective plurality of fiber paths being substantially aligned with a respective direction;
• determining an isotropy factor for the component based on the initial set of fiber paths, the isotropy factor being a measure of a distribution of the plurality of fiber paths on the surface, the isotropy factor determined, via a finite element analysis, by:
• dividing the component into a plurality of elements;
• evaluating, for each of the plurality of elements, an angular distance between the plurality of fiber paths and a mechanical strength provided by the plurality of fiber paths to obtain one or more local isotropy factors;
• and
• combining the one or more local isotropy factors into the isotropy factor;
• comparing the isotropy factor to a predetermined threshold;
• determining that the isotropy factor exceeds the predetermined threshold;
• using an automated fiber placement machine for applying, for each of the at least one ply, a respective layer of composite material to the surface of the component, wherein the unidirectional fibers of the composite material are applied along the initial set of fiber paths;
• and
• validating the initial set of fiber paths by inspecting, for each of the at least one ply, the respective layer of composite material as applied to the surface, the validating comprising:
• projecting a reference shape on the respective layer of composite material as applied to the surface;
• determining an angle between a line portion of the reference shape and an orientation of the unidirectional fibers composing the respective layer of composite material;
• comparing the angle to a predetermined value;
• validating the respective layer of composite material when the angle is lower than the predetermined value;
• and
• when the angle exceeds the predetermined value, adjusting at least one of a position and an orientation of at least some of plurality of fiber paths, thereby producing a first adjusted set of fiber paths, and repeating, using the first adjusted set of fiber paths as the initial set of fiber paths, the determining, the comparing, the applying, and the validating until the isotropy factor is below the predetermined threshold or the angle is lower than the predetermined value.