Automated tape layering for conical composite components

A method of using automated tape layering (ATL) equipment to produce a heatshield, the ATL equipment including a tape deployment head and a tape controller, the method comprising the steps, performed using the tape deployment head under automated control of the tape controller, of:

• receiving a starting portion of a tape from a tape supply, the tape having a first tape edge and a second tape edge;
• positioning the starting portion of the tape in contact with a conical tool structure;
• and
• after the starting portion of the tape is positioned in contact with the conical tool structure, maneuvering at least one of (i) the tape deployment head relative to the conical tool structure, the tape deployment head being constructed and arranged to deploy tape around the conical tool structure, and (ii) the conical tool structure relative to the tape deployment head, to deploy the tape around the conical tool structure with the first tape edge adjacent to the conical tool structure and the second tape edge extending outwardly from the conical tool structure to form the heatshield;
• wherein the tape controller includes a robotic assembly and associated control circuitry,
• wherein maneuvering includes:
• using the robotic assembly under control of the control circuitry to robotically move the conical tool structure and the tape deployment head relative to each other to precisely guide the tape around the conical tool structure;
• and
• wherein robotically moving the conical tool structure and the tape deployment head relative to each other includes:
• receiving a set of sensing signals indicating current position of the conical tool structure and the tape deployment head relative to each other, and
• based on the set of sensing signals, applying the tape under pressure to form the heatshield.