Methods and systems for manufacturing advanced composite components

A method of manufacturing a plurality of tows per course using a fiber placement system comprising at least one material storage enclosure, wherein for each tow to be produced per course, the material storage enclosure includes a material spool assembly having a material wound thereon, a swiveling roller assembly, and a redirect roller assembly;

• at least one material feeding/cutting station including a cutting mechanism;
• at least one material transfer station, wherein for each tow to be produced per course, the material transfer station includes a moveable guide tray equipped with a vacuum system;
• and at least one layup station including a vacuum table/layup surface, and a pick-and-place device equipped with an end-effector, the method comprising the steps of:
• independently pulling the material wound on each material spool assembly forward through its respective swiveling roller assembly and redirect roller assembly, so that the material wound on each material spool assembly is fed forward beyond the cutting mechanism into its respective moveable guide tray located in the material transfer station;
• after the material wound on each material spool assembly is fed a desired distance into its respective moveable guide tray, activating the vacuum system of each respective moveable guide tray, causing the material to be held in position in its respective moveable guide tray;
• after causing the material to be held in position in its respective moveable guide tray, actuating the cutting mechanism to sever the material from its respective material spool assembly, thereby creating one of the plurality of tows;
• with the material held in position in its respective moveable guide tray, moving the moveable guide trays horizontally, in a direction away from the cutting mechanism, thereby making all of the plurality of tows accessible by the pick-and-place device;
• rotating the end-effector of the pick-and-place device into alignment with the moveable guide trays;
• lowering the end-effector into contact with the plurality of tows;
• activating the end-effector;
• deactivating each vacuum system of each moveable guide tray;
• retracting the end-effector of the pick-and-place device, so as to lift the plurality of tows away from the moveable guide trays;
• positioning the end-effector of the pick-and-place device above the vacuum table/layup surface;
• lowering the end-effector of the pick-and-place device so as to place the plurality of tows into contact with the previously laid ply on the vacuum table/layup surface;
• deactivating the end-effector of the pick-and-place device;
• and
• retracting the end-effector of the pick-and-place device, leaving the plurality of tows in position atop the previously laid ply on vacuum table/layup surface.