Loop Technology automates complex prepreg layup through FibreFORM system

Loop Technology presents FibreFORM, a highly conformable system capable of picking composite plies from a flat surface and forming them onto a double curvature surface. Suitable for prepreg and dry fiber materials, FibreFORM can be used to manufacture a wide range of component types including aerospace part such as fuselage sections, wing skins, control surfaces, engine nacelles; blades for wind, tidal and engine applications; automotive panels; rail rolling stock; and radomes.

Deployed on a robot or gantry system, FibreFORM is able to carefully pick up composite plies using individually controlled suction cups (the model shown above has 270). Then, with its specially designed hand and wrist mechanisms, it reportedly manipulates the splines in such a way as to match the 3D surface of a tool, all with millimetric accuracy and precision. Loop Technology says the system can operate in fully horizontal and vertical planes or a combination of both. It can even operate in multiple orientations if the deployment system permits. Multiple modules can also be arranged in parallel, enabling the construction of systems capable of laying up wing skins up to 20+ meters long.

According to Loop Technology, the automated system performs 10x the deposition rate at three times the speed — up to 200 kg/hour — when compared to traditional handling methods. It also ensures positional repeatability of ±1 mm, though this is subject to material type and geometry.