Fives introduces COAST in-process composite inspection technology

Global industrial engineering solutions company Fives (Hebron, Ken., U.S. and Paris, France) announces the launch of its in-process composite inspection technology, COAST (Composite Optical Automated Surface Tracking). COAST is statistically capable of measuring material defects in the automated fiber placement (AFP) process, including gaps, twists, tow end placement and missing tows on complex, contoured surfaces.

The technology incorporates optical coherence tomography (OCT), a laser-based technology adapted from the medical industry to create highly accurate surface profiles during the AFP manufacturing process. According to Fives, these surface measurements are seamlessly integrated with machine position data, computer-aided manufacturing (CAM) data and advanced computer vision algorithms to detect material defects in real time.

One of COAST’s primary advantages is evident in the signal quality comparison during machine head rotation. When an AFP machine head rotates 20º to create a contour, the LLT signal degrades from 100% quality to 78%, whereas the OCT signal only degrades from 99% to 95%. This signal quality difference becomes more significant with increased machine head rotation.

Moreover, precise 3D point cloud generated by COAST serves as input for defect detection algorithms, monitoring process variability and helping to identify the probability and location of material defects.

Manual inspection, while effective, relies on human operators and lacks the ability to capture detailed data over extended periods, introducing additional variability into the manufacturing process. COAST addresses these limitations by automating data collection and quality analysis throughout the part’s lifecycle. In the design phase, designers receive instant, detailed feedback on prototypes produced by AFP machines, facilitating rapid iterations and optimal parameter discovery. During production, manufacturing engineers gain continuous feedback on surface quality and defect locations, ensuring the health of their process.

In June 2023, COAST was successfully deployed in a customer facility, demonstrating its ability to allow operators to assess material defects more quickly than manual inspection techniques. Further enhancements to the user interface are on the horizon, with a projected 90% reduction in inspection and rework time by 2024.

According to Fives, COAST is poised to transform AFP quality specifications, shifting from a ply-by-ply approach to a holistic 3D perspective, aligning composite quality more closely with the true physical properties of the material under study. Additionally, it is believed that COAST will drive the widespread adoption of AFP by increasing overall equipment effectiveness (OEE); preliminary assessments show that OEE can increase by 30% with the full integration of in-process inspection (IPI) technology, translating into a significant cost reduction for AFP end users.

The COAST “1.0” product is currently available for integration into any Fives AFP machine, with discussions underway to integrate it into third-party AFP machines. Ongoing R&D efforts aim to expand the system’s data collection capabilities and acquisition rates, addressing the evolving needs of the AFP industry.

COAST is the result of two pivotal collaborations. Fives partnered with the Canadian National Research Council (CNRC) to integrate OCT technology into AFP machines and a current customer that has extensively tested and adopted IPI, resulting in a tangible reduction in inspection time and increased workflow efficiency.