Tape structure of a tape for use in manufacturing a composite structure, automated fiber placement (afp) device, automated fiber placement (afp) method and composite structure

An automated fiber placement device having a moveable laying head for tape placement in an automated fiber placement (AFP) method, comprising:

• a tape structure of a tape for use in manufacturing a composite structure, the tape structure comprising a layer of unidirectional pre-impregnated dry fibers embedded in a thermosetting polymer matrix, with the thermosetting polymer matrix having a composition comprising:
• between 20% and 50%, or between 25% and 40% by weight of a polymer matrix of at least one first monomer or oligomer;
• between 30% and 60%, or between 35% and 40% by weight of a polymer matrix of at least one second monomer or oligomer;
• between 4% and 25%, or between 4% and 7% by weight of a polymer matrix of at least one curing agent;
• between 0.5% and 5%, or between 0.8% and 1.5% by weight of a polymer matrix of at least one reactive chain extender;
• and
• at least one additive, or additive configured as a toughening agent, wherein the polymer matrix is configured to be solid or semi-solid in a first temperature range and softened in a second temperature range different from the first temperature range;
• a feeding device for feeding the tape to a region of placement;
• a temperature control unit configured to increase a processing temperature of the tape structure before or during placement above a temperature range of between 15° C. and 25°, or between 18° C. and 21° to soften the tape structure;
• a deposition device for placing and/or compacting the tape structure on a composite structure or a previous laminated layer formed on the composite structure;
• and
• a compaction device for establishing a permanent connection between the tape and the composite structure or a previous laminated layer formed on the composite structure with the compaction device being configured to apply at least one of pressure, heat, and electrical current to the tape during or after placement, wherein the feeding device, the temperature control unit, the deposition device and the compaction device are positioned adjacent to the laying head and configured to move together with the laying head.