Systems and Methods for Thermal Spraying of Protective Materials onto Composite Laminates

A non-transitory computer readable medium comprising program instructions executable by one or more processors to perform the operations comprising:

• determining one or more parameters for depositing a material, using a thermal sprayer, onto each of a plurality of composite laminate structures;
• depositing, using the thermal sprayer, a first layer of the material onto a surface of each of the plurality of composite laminate structures;
• cooling, subsequent to depositing the first layer of the material, the plurality of composite laminate structures;
• depositing, using the thermal sprayer, a second layer of the material onto the first layer of material on each of the plurality of composite laminate structures;
• cooling, subsequent to depositing the second layer of the material, the plurality of composite laminate structures;
• determining, for each of the plurality of composite laminate structures, (i) a remaining number of layers of the material to deposit and (ii) a deposition location for each of the remaining layers of the material;
• and
• depositing, using the thermal sprayer, the determined remaining number of layers of the material at the determined deposition location on each of the plurality of composite laminate structures.