Systems and Methods for Actualizing Simulated Scarfs and Patches for Repair of Composite Laminates

A method for repairing a composite structure, the method comprising:

• acquiring discrepancy data that defines a location and size of a discrepancy on a surface of a composite laminate;
• analyzing the acquired data to determine an optimal scarf shape and repair methodology;
• retrieving model data for the composite laminate from data storage;
• creating a discrepancy sketch of the discrepancy based at least in part on the discrepancy data and the model data;
• generating a scarfed laminate model having a virtual scarfed surface in accordance with a policy defining how to create the virtual scarfed surface based on the discrepancy sketch;
• generating a virtual patch that matches the virtual scarfed surface in accordance with an optimization algorithm and the policy, the virtual patch comprising virtual repair plies with ply overlaps and virtual structural plies;
• creating flattened ply contours of the virtual repair plies and virtual structural plies on a planar surface to support automated ply cutting;
• and
• exporting digital files specifying the flattened ply contours for use by a ply cutting machine.

A system comprising:

• a computer;
• a memory in communication with the computer;
• and an application stored in the memory and executable by the computer, wherein the application comprises:
• a user interface;
• a simulation software module configured to perform functions including discrepancy damage definition and scarf repair creation;
• and
• a first post-simulation software module that enables the computer to generate code for controlling robotic machining of a scarf, which code is dependent on results of the discrepancy damage definition and scarf repair creation.