Automated tape layering for a composite

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