Reduced complexity automatic fiber placement apparatus and method

A method of placing composite fiber tape on a substrate using an automatic fiber placement head, comprising:

• moving the fiber placement head across the substrate from a starting position to an ending position;
• sequentially starting the placement of individual fiber tape strips onto the substrate to form a band as the placement head moves from the starting position to the ending position;
• and,
• cutting all of the tape strips in the band substantially simultaneously at the ending position.

A method of forming a composite fiber layup on a substrate having a substrate feature, comprising:

• moving an automatic tape placement head across the substrate away from the substrate feature in a first direction;
• using the placement head to lay down a first band of composite tape strips as the placement head moves across the substrate in the first direction, including staggering the starting points of at least certain of the tape strips in the first group to form a first ramp pattern on one side of the substrate feature;
• cutting all of the tape strips in the first band at an ending point of the tape strips in the first band;
• moving the automatic tape placement head across the substrate away from the substrate feature in a second direction;
• using the placement head to lay down a second band of composite tape strips as the placement head moves across the substrate in the second direction, including staggering the starting points of at least certain of the tape strips in the second band to form a second ramp pattern on another side of the substrate feature;
• and,
• cutting all of the tape strips in the second band at an ending point of the tape strips in the second band.

A fiber tape placement apparatus for placing fiber tape on a substrate, comprising:

• a plurality of tape supply devices each holding a supply of fiber tape;
• a device for compacting the tape on the substrate;
• a plurality of threading mechanisms respectively associated with the tape supply devices and each operable for initiating tape feed from one of the tape supply devices to the compaction device;
• and,
• a cutting device including a single cutting blade for cutting the ends of all of the tapes fed to the compaction device substantially simultaneously.

A method of forming a contoured composite layup using an automatic fiber tape placement machine, comprising:

• moving an automatic tape placement head across a tool;
• feeding a plurality of fiber tapes from tape supplies to threading devices;
• using the threading devices to sequentially start feeding of the tapes to a compaction roller and generate a contour in the layup;
• applying and compacting the tapes on the tool using the compaction roller;
• and,
• cutting the ends of all of the tapes substantially simultaneously using a single cutter.

A fiber tape placement head for placing fiber tape on a substrate having a feature, comprising:

• a plurality of tape supply devices each holding a supply of the tape;
• a plurality of guides for guiding the movement of the tapes;
• a plurality of threading mechanisms for respectively starting tape feed from the tape supply devices;
• a compaction roller for receiving the tape fed by the threading mechanisms and for compacting the tape on the substrate;
• and,
• a tape cutting mechanism between the threading mechanisms and the compaction roller, the cutting mechanism including a single actuator and a single cutting blade for simultaneously cutting the ends of all of the tapes in a single stroke.