Patent Publication Number: US-2022234310-A1

Title: Material dispensing systems

Description:
CROSS-REFERECE TO RELATED APPLICATION 
     This patent application is a divisional of U.S. patent application Ser. No 16/031,452, filed Jul. 10, 2018. The disclosure of which is hereby incorporated by reference. 
    
    
     GOVERNMENT RIGHTS 
     At least some of the subject matter of this application may have been made with government support under contract number NWA6000522-0014. The government may have certain rights in the invention. 
    
    
     BACKGROUND 
     Field of the Invention: 
     The present disclosure relates, in general, to composite laminates, and in particular, to the manufacture of composite laminates using a material dispensing system. 
     Description of Related Art: 
     Modern aircraft are manufactured from a wide variety of materials, including steel, aluminum, and a wide variety of composite materials. Most structural components are made from strong, rigid materials. However, in order to conserve weight, the structural components are often made from a thin layer of metal or composite that includes reinforcement strips of material reinforced with stringers. 
     Tiltrotor aircraft have complicated proprotor assemblies located at opposing wing tips that operate between a helicopter mode to take off, hover, fly, and land like a conventional helicopter; and an airplane mode. The proprotor assemblies are oriented vertically for a helicopter mode and horizontally for airplane mode. Because the tiltrotor aircraft must operate in both helicopter mode and airplane mode, and operate while transitioning between the two, the wing structure must support the weight of the proprotor assemblies, withstand the forces generated from the proprotor assemblies in a variety of modes, and provide a lifting force sufficient to lift the weight of the aircraft. 
       FIG. 1  is a partial view of an exemplary prior art tiltrotor wing  10  including a torque box structure  30 . The torque box structure  30  includes skins  20 , forward spar  32 , and aft spar  34 . The skins  20  includes stringers  12  extending generally parallel to the longitudinal axis of the wing  10 . The upper skin  20  requires five stringers  12  and the lower skin  20  requires four stringers  12 . The stringers  12  provide stiffness and support to the skin  20  and are each an I-beam shaped stiffener as shown in  FIG. 2  connected to the interior surface  20 a of the skin  20 . The stiffeners  12  are made from a composite material and extend the depth of the skin  20  assembly into the interior of the wing  10  thereby reducing the space available for fuel and other internal systems. 
     The skin  20  is constructed of many of layers or “plies” of composite materials comprised of hundreds of reinforcement strips  28  or “postage stamps” made of various types, sizes, orientations, and thicknesses of materials. The reinforcement strips  28  are made of graduated sizes of postage stamp stamps that have been compacted together as shown in  FIG. 2 . The reinforcement strips  28  are located below the stringer  12 : (1) to provide support for the skin  20  against catastrophic buckling; (2) to maintain shape and contour of the skin  20 ; (3) to provide stiffness at the stringer load points; and (4) to distribute pressure into the skin. During manufacture of the skin  20  each reinforcement strips  28  is cut, labeled, and positioned in a mold, which is an extremely time-consuming and laborious process. 
     Each reinforcement strip  28  is typically cut from a ply of pre-impregnated material (pre-preg) made of reinforcing fibers such as carbon, glass, aramid, and the like, that are bonded together with a thermoplastic polymer. Pre-preg conventionally has been supplied by manufacturers as 0° tape (with all its fibers orientated in one direction in relation to an edge of the pre-preg roll) or 0/90 fabric (continuous fiber in the roll-up direction, 0°, with discontinuous woven or stitched fibers running transverse to the roll-up direction, 90° having a width between about 75 and 300 mm. Often, to achieve a desired laminate characteristic, the plies of pre-preg are layered with their fibers having different orientations in relation to each other to tailor the structural properties of the laminates. For example, in applications for forming high strength-low weight complex shaped structures it may be desired to apply and form one layer of pre-preg at a time on a tool with one or more of the different layers having different fiber orientations than another layer. Examples of common layer orientations, besides 0 degree and 0/90 degree, include, but are not limited to, 30°, 45°, 60°, 90°, 120°, 135°, and 150°. Combinations of these layer orientations are also needed including, but not limited to, 45°/135°, 60°/150°, 30°/120°. 
     The cutting and placement of the reinforcement strips  28  in different orientations is a complex process that is tedious and time consuming. Accordingly, automated tape laying (ATL) or automated fiber placement (AFP) machines have been developed to perform these steps. ATL or AFP machines use tapes or tows distributed from a moving head that places and cuts reinforcement strips  28  on a mold or mandrel in an automatic fashion. For instance, ATL machines use one or more tapes each having a width between about 75 and 300 mm, whereas AFP machines use a number of small width tows that are typically less than about 8 mm wide. The fibers in tape are usually oriented at either 0° or 90°. The tape or tow is fed into a roller head, where heat is applied thereto prior to its deposition onto a substrate. The position of the roller head is constantly moving and repositioned for placement of each ply having a desired orientation on the mold. The roller head may also heat the substrate onto which the tape or tow is to be deposited (typically this may be a layer of tape deposited in a previous step). Under pressure from the roller and/or tension, the tape or tow becomes bonded to a substrate as the thermoplastic polymer within the composite, and within the substrate, melts and adheres the tape or tow to the substrate. Then cooling and solidification of the thermoplastic polymer leads to consolidation of the tape as part of the substrate to which it was applied. Typical manufacturing velocities for the rate of laydown of tape are from 0.1 m/min up to 60 m/min, preferably from 1 m/min up to 60 m/min. As production velocities increase, there is a risk that the degree of bonding of the tape or tow to the substrate may decrease and this can lead to the tape or tow delaminating from the substrate. Moreover, depending upon the size and thickness of a composite article for a skin of a tiltrotor wing, complicated robotics repeat complicated placement steps of narrow tape or tow that occur over hours. ATL tends to achieve a much higher deposition rate compared to AFP, but also produces much more waste. 
     Accordingly, the need has arisen for an improved material dispensing system for the manufacture of composite articles for use on a tiltrotor aircraft that addresses one or more of the foregoing issues. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The novel features believed characteristic of the embodiments of the present disclosure are set forth in the appended claims. However, the embodiments themselves, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a cross-sectional view of a prior art tiltrotor wing; 
         FIG. 2  is a cross-sectional view of a stringer and skin in the prior art tiltrotor wing shown in  FIG. 1 ; 
         FIG. 3  is a perspective view of a tiltrotor aircraft in helicopter mode, according to one example embodiment; 
         FIG. 4  is a perspective view of a tiltrotor aircraft in airplane mode, according to one example embodiment; 
         FIG. 5  is a schematic perspective view of a material dispensing system, according to an exemplary embodiment; 
         FIG. 6  is a schematic side view of the material dispensing system in  FIG. 5 ; 
         FIG. 7A  is a perspective, section view of a bias ply and non-bias plies, according to an illustrative embodiment; 
         FIG. 7B  is a perspective, section view of bias plies and non-plies, according to an exemplary embodiment; 
         FIG. 8  is a flow diagram of a method of preparing a composite article, according to an exemplary embodiment; 
         FIG. 9  is another embodiment of a material dispensing system with a plurality of dispensing heads, according to an illustrative embodiment; 
         FIG. 10  is an embodiment of a material dispensing system where the frame is a robotic arm; and 
         FIG. 11  is an embodiment of a material dispensing system where the frame is a gantry, according to an exemplary embodiment. 
     
    
    
     SUMMARY 
     In a first aspect, there is a material dispensing system including a first frame; and a first application head supported by the first frame including a first bias ply assembly comprising a bias ply roll supported on a bias ply dispenser unit, the first bias ply assembly configured to pass bias ply material along a bias path; and a first non-bias ply assembly comprising a non-bias ply roll supported by a non-bias ply dispenser unit, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; wherein the bias path and the non-bias path are substantially parallel. 
     In an embodiment, the first bias ply roll is comprised of a fiber having a bias orientation. 
     In an exemplary embodiment, the bias orientation is at least one of the following: about 15°, about 30°, about 45°, about 60°, about 75°, about 105°, about 120°, about 135°, about 150°, and about 165. 
     In an embodiment, the non-bias ply roll is comprised of a fiber having a non-bias orientation. 
     In another embodiment, the non-bias orientation is at least one of the following: about 0°, about 90°, about 180°, and 270°. 
     In an illustrative embodiment, at least one of the bias ply roll and the non-bias ply roll are comprised of a ply having a selected width greater than 24 inches. 
     In an embodiment, the first biased assembly and the first non-biased assembly are in a stacked horizontal configuration on the first application head. 
     In another embodiment, at least one of the bias ply roll and the non-bias ply roll is a ply of resin impregnated fibers. 
     In an embodiment, the system includes a cutter slidably coupled to the first application head and configured to cut at least along a width of a bias or non-bias ply. 
     In yet another embodiment, the system includes an adhesive delivery device. 
     In an embodiment, the first application head moves only in an X direction during operation. 
     In an embodiment, the first frame includes at least one of the following: a pair of movable support members, a gantry, and a robotic arm. 
     In still another embodiment, the movable support members move along a track. 
     In yet another embodiment, the system is programmable. 
     In a second aspect, there is a material dispensing system including a first frame; a first application head supported by the first frame, the first application head including a non-bias ply assembly, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; a second frame; and a second application head supported by the second frame, the second application head including a bias ply assembly, the bias ply assembly configured to pass bias ply material along a bias path; wherein the first frame and the second frame move in an X direction during operation. 
     In an embodiment, the bias path and the non-bias path are substantially parallel. 
     In a third aspect, there is a method of preparing a composite article including: providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel. 
     In an embodiment, the first bias assembly and the first non-bias assembly are disposed on a frame. 
     In an illustrative embodiment, the first bias assembly is disposed on a first frame and the first non-bias assembly is disposed on a second frame. 
     In an exemplary embodiment, the method includes a step of cutting a reinforcement strip from at least one of the bias ply and the non-bias ply. 
     Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Illustrative embodiments of material dispensing systems and methods therefor are described below. In the interest of clarity, all features of an actual implementation may not be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer&#39;s specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
     In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction. 
     Referring to  FIGS. 3 and 4 , a tiltrotor aircraft  101  is illustrated. Tiltrotor aircraft  101  can include a fuselage  103 , a landing gear  105 , a tail member  107 , a wing  109 , a propulsion system  111 , and a propulsion system  113 . Each propulsion system  111 ,  113  includes a fixed engine and a rotatable proprotor  115 ,  117 , respectively. Each rotatable proprotor  115 ,  117  have a plurality of rotor blades  119 ,  121 , respectively, associated therewith. The position of proprotors  115 ,  117 , as well as the pitch of rotor blades  119 ,  121 , can be selectively controlled in order to selectively control direction, thrust, and lift of tiltrotor aircraft  101 . 
       FIG. 3  illustrates tiltrotor aircraft  101  in helicopter mode, in which proprotors  115  and  117  are positioned substantially vertical to provide a lifting thrust.  FIG. 4  illustrates tiltrotor aircraft  101  in an airplane mode, in which proprotors  115 ,  117  are positioned substantially horizontal to provide a forward thrust in which a lifting force is supplied by wing  109 . It should be appreciated that tiltrotor aircraft can be operated such that proprotors  115 ,  117  are selectively positioned between airplane mode and helicopter mode, which can be referred to as a conversion mode. 
     The proprotors  115  and  117  rotate from a conversion axis C located above an upper wing skin  123 . An advantage of locating the conversion axis C of the proprotors  115  and  117  above the upper wing skin  123  is that the fore/aft location of the proprotors  115  and  117  can be moved to shift the center of gravity of the aircraft in the various flight modes as described by U.S. Pat. No. 9,174,731, issued Nov. 3, 2015, which is hereby incorporated by reference in its entirety. As such, locating the conversion axis of the proprotors  115  and  117  above the upper wing skin  123  allows the fore/aft location of the proprotors  115  and  117  to be optimized for the center of lift in a particular flight mode. 
     The aircraft  101  has a maximum range further than a conventional tiltrotor aircraft (wing shown in  FIGS. 1 and 2 ) achieved at least in part by the wing structure including the wing skin  123 . The wing structure  109  provides structural support for the propulsion systems  111 ,  113  and fuselage  103  and lifting force sufficient to lift the weight of the aircraft  101 . The wing structure  109  is configured to distribute loads and the shearing motion generated by the propulsion systems  111 ,  113  during the various flight modes. The improved structural support of the wing member  109  also provides fuel bays having no I-beam projections on the fuel supporting surfaces, which provides more space in the fuel bay for fuel capacity. 
     This disclosure depicts and describes material dispensing systems and methods relating thereto that can be used to manufacture the wing skin  123  and other composite articles for the tiltrotor wing structure  109 . The material dispensing systems, components and features thereof, and methods relating thereto depicted and/or described herein can be used with any aircraft having one or more composite articles, including tiltrotor aircrafts, helicopters, tilt wing aircrafts, unmanned aerial vehicles (UAVs), hovercrafts, and other vertical lift or VTOL aircrafts, or can further be used with any device having a composite component, including devices with propellers, windmills, and turbines. Further, any features of one embodiment of the material dispensing systems and methods relating thereto in this disclosure can be used with any other embodiment of the material dispensing systems and methods in this disclosure such that the other embodiment has the same or similar features, operates in the same or similar way, or achieves the same or similar functions. Some components of this disclosure are depicted by graphic shapes and symbols. Unless this disclosure specifies otherwise, such components should be understood to include the same or similar characteristics and features as those components that are named or described, though the graphic shapes and symbols may not depict each such characteristic or feature. 
     In an embodiment, as shown in  FIGS. 5-6 , a material dispensing system  200  includes a first frame  220 , a first application head  230  supported by the first frame  220 , and a mold  224 . The first application head  230  is configured to dispense, cut, and apply plies from a first bias ply assembly  240  and a first non-bias ply assembly  250  onto the mold  224 . The mold  224  is disposed on a machine base  226 . 
     In an embodiment, the first frame  220  includes movable support members  222  disposed in a pair of tracks  225 . In the illustrative embodiment, the tracks  225  are mounted in the floor; however, in other embodiments, the tracks  225  are mounted to or in a ceiling or a wall. In some illustrative embodiments, the first frame  220  includes a drive system  227  that permits the movable support members  222  to traverse across the tracks  225  during operation. In an embodiment, the drive system  227  includes wheels  228  operably connected to the movable support members  222  and received in a groove in the tracks  225 . In an embodiment, the drive system  227  includes an electric motor  229  for driving wheels  228  on tracks  225 . In other embodiments, drive system  227  can include sprockets, chains, and/or axles to move support members  222 . 
     In an embodiment, the first frame  220  and the first application head  230  are designed to move in only in an X motion direction as depicted in  FIG. 5 . The X motion is motion along a longitudinal axis X. The Y motion is motion along the transverse axis Y that is perpendicular to longitudinal axis X. The Z motion is motion along a vertical axis Z. In some embodiments, the first application head  230  is designed to move in a Z motion. Advantageously the first frame  220  and the first application head  230  cannot and do not move in a Y motion, which eliminates robotic placement systems used in ATL and AFT machines. Accordingly, the material dispensing system  200  reduces operating costs, manufacturing time, and maintenance as compared to conventional placement systems (e.g., ATL and AFT machines). 
     In an illustrative embodiment, the first application head  230  is disposed generally at the top and front of the first frame  220 . The first application head  230  includes one or more first bias ply assemblies  240  (e.g., a second, third, fourth, or fifth bias ply assemblies). The number and size (width) of the bias ply assemblies can depend on the type of the bias material and desired orientation of the bias ply material desired for the composite. The first application head  230  can include one or more first non-bias ply assemblies (e.g., a second, third, fourth, or fifth bias ply assemblies). The number and size (width) of the non-bias ply assemblies can depend on the type of non-bias material and desired orientation of the non-bias ply material desired for the composite. 
     In the illustrative embodiment, the first application head  230  includes the first biased assembly  240 , the first non-biased assembly  250 , and, optionally, a second non-biased assembly  270  in a stacked horizontal configuration such that the longitudinal axis of each assembly  240 ,  250 ,  270  is substantially perpendicular to the tracks  225  during operation. In other embodiments, the first application head  230  can comprise a platform on the first frame  220  with mounting brackets for supporting the first biased assembly  240  and the first non-biased assembly  250 . 
     The first bias ply assembly  240  includes first a bias ply roll  242  supported on a bias ply dispenser unit  244 . The bias ply roll  242  is comprised of one ply of a tape or fabric having a selected width that is composed of fibers having a bias orientation. The fabric of the bias ply roll  242  can be comprised of a bidirectional weave (for example, but not limitation, 45° and 135°) in a biased orientation. The bidirectional weave can include at least one of the following, but is not limited to, a plain weave, 8 harness satin weave, 4 shaft satin weave, 8 shaft satin weave, crowfoot satin weave, 5 harness satin weave, and 8 shaft satin weave. The tape of the bias ply roll  242  can be comprised of unidirectional fibers (not woven) in a biased orientation. In an exemplary embodiment, the selected width is at least one of the following: greater than 24 inches, greater than 48 inches, greater than 50 inches, greater than 60 inches, greater than 64 inches. The selected width of the bias ply roll  242  is greater than ATL or AFP machines so as to substantially increase the manufacturing and reduce the complexity of the system  200  as compared to conventional ATL or AFP machines. The fibers in the bias ply roll  242  can be continuous filaments or fibers including one or more of glass, carbon, graphite, basalt, an aromatic polyamide (i.e. “aramid”) material, a variant of an aromatic polyamide material (e.g., a polyparaphenylene terephthalamide material, such as Kevlar® by E.I. du Pont de Nemours and Company of Richmond, Va.), or the like. 
     In addition, the fibers of the bias ply roll  242  have a bias orientation. Bias orientation means a fiber having an oblique angle relative to center axis  201   a  (e.g., an oblique angle is neither parallel nor at right angles to center axis  201   a ). For example, the bias orientation is a fiber having an angle not oriented at either 0°, 90°, 180°, or 270° relative to a center axis  201   a  of the composite article. In an embodiment, the bias orientation of the fiber has angle of in varying orientations about 15°, about 30°, about 45°, about 60°, about 75°, about 105°, about 120°, about 135°, about 150°, and/or about 165° relative to the center axis  201   a  of the composite article; however, it should be appreciated that the bias orientation of a fiber can be any angle having an oblique orientation (e.g., any angle more than 0° and less than 90°, greater than 90° and less than 180°, greater than 180° and less than 270°, and greater than 270° and less than) 360°. In the illustrative embodiment shown in  FIG. 5 , the first bias ply roll  242  is a ply with a bias weave fabric having a bias orientation of about 45° and 135°. In another exemplary embodiment, a ply  212  of unidirectional tape having a bias orientation of about 45° in  FIG. 7A . In another illustrative embodiment shown in  FIG. 7B , plies  212 ,  215  of unidirectional tape have a bias orientation of about 45° and plies  213 ,  214  of unidirectional tape have a bias orientation of about 135°. 
     The bias ply dispenser unit  244  can be a conventional fabric dispensing drive. In an embodiment, the bias ply dispenser unit  244  is a variable speed drive to dispense the bias ply from the bias ply roll  242  onto the mold  224 . 
     The first bias ply assembly  240  is configured to pass bias ply material along a bias path  246 . The bias path  246  is parallel to the tracks  225 . In the illustrative embodiment, the bias path  246  is parallel to the longitudinal and center axis  201  of the composite article  201 . It will be appreciated that one of the novel features of the material dispensing systems and methods herein is the use of a bias ply roll  242  with fibers having a bias orientation. Advantageously the fibers in the bias orientation in the bias ply roll  242  permit the mere dispensing of the ply from the first bias ply assembly along the bias path  246 . The orientation of the first bias ply roll  242  and assembly  240  remains perpendicular to the longitudinal and center axis  201  of the composite article  201  during operation of the system  200 , thereby increasing dispensing velocities and eliminating complex and expensive dispensing heads used by ATL and AFP machines. 
     The first non-bias ply assembly  250  includes first a non-bias ply roll  252  supported on a non-bias ply dispenser unit  254 . The non-bias ply roll  252  is comprised of one ply of a tape or fabric having a selected width that is composed of fibers having a non-bias orientation. The fabric of the non-bias ply roll  252  can be comprised of a bidirectional weave (for example, but not limitation, 0° and 90°) in a non-biased orientation. The bidirectional weave can include at least one of the following: a plain weave, 8 harness satin weave, 4 shaft satin weave, 8 shaft satin weave, crowfoot satin weave, 5 harness satin weave, and 8 shaft satin weave. The tape of the non-bias ply roll  252  includes, but is not limited to, unidirectional fibers (not woven) in a non-biased orientation (for example, but not limitation, fibers at 0° or 90° relative to the center axis  201   a ). Tape of the non-bias ply roll is commonly referred to as Uni. In an exemplary embodiment, the selected width is at least one of the following: greater than 24 inches, greater than 48 inches, greater than 50 inches, greater than 60 inches, greater than 64 inches. The selected width of the non-bias ply roll  252  is greater than ATL or AFP machines so as to substantially increase the manufacturing and reduce the complexity of the system  200  as compared to conventional ATL or AFP machines. The fibers in the non-bias ply roll  252  can be continuous filaments or fibers including one or more of glass, carbon, graphite, basalt, an aromatic polyamide (i.e. “aramid”) material, a variant of an aromatic polyamide material (e.g., a polyparaphenylene terephthalamide material, such as Kevlar® by E.I. du Pont de Nemours and Company of Richmond, Va.), or the like. 
     In addition, the fibers of the non-bias ply roll  252  have a non-bias orientation. A non-bias orientation is a fiber having an angle that is parallel or at right angles to center axis  201   a  (e.g., the fiber is oriented at about 0°, about 90°, about 180°, or about 270° relative to center axis  201   a  of the composite article). In the illustrative embodiment shown in  FIG. 5 , the first non-bias ply roll  252  includes, but is not limited to, unidirectional tape having a non-bias orientation of about 0°. In another exemplary embodiment shown in  FIG. 7A , a ply  210  of unidirectional tape has a non-bias orientation of about 0° and a ply  211  of plain weave fabric has fibers in non-bias orientations of about 0° and 90°. In another illustrative embodiment shown in  FIG. 7B , plies  210 ,  217  of unidirectional tape have a non-bias orientation of about 0° and plies  211 ,  216  of unidirectional tape have a non-bias orientation of about 90°. 
     The non-bias ply dispenser unit  254  can be a conventional fabric dispensing drive. In an embodiment, the non-bias ply dispenser unit  254  is a variable speed drive to dispense the non-bias ply from the non-bias ply roll  252  onto the mold  224 . 
     The first non-bias ply assembly  250  is configured to pass a non-bias ply material along a non-bias path  256 . The non-bias path  256  is parallel to the tracks  225 . In the illustrative embodiment, the non-bias path  256  is parallel to the longitudinal and center axis  201  of the composite article  201 . The orientation of the first non-bias ply roll  252  and assembly  250  remains perpendicular to the longitudinal and center axis  201  of the composite article  201  during operation of the system  200 . In an embodiment, bias path  246  and the non-bias path  256  are substantially parallel and, in the illustrative embodiment, the bias and non-bias paths  246 ,  256  are substantially identical, which can improve dispensing velocities and eliminating complex and expensive dispensing heads used by ATL and AFP machines. 
     In some embodiments, as shown in  FIG. 5 , the first application head  230  includes a second non-bias ply assembly  270  comprising a second non-bias ply roll  272  supported by a second non-bias ply dispenser unit  274 . The second non-bias ply assembly  270  is configured to pass non-bias ply material along a second non-bias path  276 . In an embodiment, bias path  246  and the first and second non-bias paths  256 ,  276  are substantially parallel and, in the illustrative embodiment, the bias and first and second non-bias paths  246 ,  256 ,  276  are substantially identical. In the illustrative embodiment shown in  FIG. 5 , the second non-bias ply roll  272  is a plain-weave fabric having a non-bias orientation of about 0° and about 90°. 
     During operation, as illustrated in  FIGS. 5-6 , the first application head  230  is positioned on the track  225  for dispensing a selected ply from the ply roll (e.g., rolls  242 ,  252 , or  272 ) for a desired ply layout. In an exemplary embodiment shown in  FIG. 6 , each ply roll is associated with a tension member  238  to impart tension on the ply as it is being placed on the mold  224 . The tension member  238  is supported by the first application head  230 . In an embodiment, an end of the ply can be secured to the mold  224  by a conventional means such as a material clamp or weight  223 . In an embodiment, as the first frame  220  moves on the tracks  225  to the selected position for the desired ply location on the mold  224 , the ply is dispensed from the respective roll  242 ,  252 ,  272 . In some embodiments, sensors on the mold  224  can be in communication with a control computer  286  that controls and drives the bias and non-bias dispenser units  244 ,  254 ,  274  to dispense a ply onto the mold  224 . 
     In an illustrative embodiment, as shown in  FIGS. 5-6 , the first application head  230  includes a cutter  280 . The cutter  280  is slidably coupled to the front surface of the first application head  230  and is configured to cut at least along the width of the plies being dispensed therefrom. In an embodiment, the cutter  280  slides across the width of the plies as well as vertically along a track  282 . In some embodiments, the cutter can be movable and configured to perform the step of cutting a ply from at least one roll  242 ,  252 ,  272  and, optional, the step of cutting a ply reinforcement strip from a ply on at least one roll  242 ,  252 ,  272 . In some embodiments, the step of cutting occurs as the ply is dispensed from the respective roll  242 ,  252 ,  272 . In some embodiments, the cutter  280  performs the step of cutting when the ply is dispensed and at least partially on the mold  224 . In some embodiments, the cutter  280  is a laser cutter and/or other suitable device. In some embodiments, the cutter  280  can perform the step of trimming. In an embodiment, the cutter  280  is in communication with the control computer  286  to selectively adjust the cutting and trimming of the ply. 
     Once the ply and/or reinforcement strip has been dispensed, cut, and positioned onto the mold  224 , the first application head  230  is repositioned and the process starts again until the layers of the composite article  201  are complete. 
     In an embodiment, the material dispensing system  200  includes a control computer  286  communicably connected to at least one controllable components (e.g., the dispenser units  244 ,  254 ,  274 ; the drive system  227 ; the cutter  280 ). In an embodiment, the control computer  286  is connected via wires  288  or through a wireless network  204 . The control computer  286  can be programmable to optimize ply dispensing, placement, and cutting as described herein with regard to the control computer  286 . The control computer  286  includes memory  286   a  and a processor  286   b . The memory  286   a  stores ply layout parameters  287  for composite articles including the bias orientation, non-bias orientation, weave, type of ply (e.g., tape or fabric) etc. The processor  286   b  includes a programming module  289   a  for generating dispensing, placement, and cutting programs and a validation module  289   b  for validating the results. At a high level, the programming module  289   a  receives a selection of a component and ply layout parameters and selects a configuration for the first application head  230  and operating parameters  285  for the dispensing, placement, and cutting steps. The programming module  289   a  evaluates sequences of motions based on the ply layout geometry identified in the ply layout parameters  287  and selects a sequence of motions based on, for example, but not limitation, the compressive strength of the composite article  201 . Once selected, the programming module  289   a  automatically generates a dispensing, placement, and cutting program  291  based on the selected sequence of motions and the operating parameters  285 . The programming module  289   a  can transmit the dispensing, placement, and cutting program  291  to the material dispensing system  200  through the network  204 . In an embodiment, the dispensing, placement, and cutting program  291  is reviewed by a validation module  289   b . The validation module  289   b  evaluates a model of a composite article generated from the dispensing, placement, and cutting program  291  to ensure the composite article will meet operating specifications. 
     As for a more detailed description of the illustrated implementation, the control computer  286  includes memory  286   a  and the processor  286   b  and comprises an electronic computing device operable to receive, transmit, process and store data associated with system  200 . For example, the control computer  286  may be any computer or processing device such as a mainframe, a blade server, general-purpose personal computer (PC), Macintosh, workstation, Unix-based computer, or any other suitable device. Generally,  FIG. 5  provides merely one example of a computer that may be used with the disclosure. In other words, the present disclosure contemplates computers other than general purpose computers as well as computers without conventional operating systems. As used in this document, the term “computer” is intended to encompass a personal computer, workstation, network computer, or any other suitable processing device. For example, although  FIG. 5  illustrates one control computer  286  that may be used with the disclosure, system  200  can be implemented using a pool of computers. 
     Memory  286   a  may include any memory or database module and may take the form of volatile or non-volatile memory including magnetic media, optical media, Random Access Memory (RAM), Read Only Memory (ROM), removable media, or any other suitable local or remote memory component. In the illustrated implementation, memory  286   a  includes operating parameters  285 , ply layout parameters  287 , and dispensing, placement, and cutting program  291 . Ply layout parameters  287  include one or more entries or data structures that identify ply geometry, bias orientation, non-bias orientation, and associated features. 
     Operating parameters  285  include any parameters, variables, algorithms, instructions, rules, objects or other directives for operating a particular material dispensing system  200  to perform dispensing, placement, and cutting of plies from rolls  242 ,  252 ,  272  for a composite article  201 . 
     The dispensing, placement, and cutting program  291  is any application, program, module, process, or other software that may generate commands to execute dispensing, placement, and cutting of plies from rolls  242 ,  252 ,  272  using the material dispensing system  200 . For example, the dispensing, placement, and cutting program  291  may generate commands to control the position of the first frame  220  (via drive system  227 ) through a sequence of motions or paths and stopping at predefined points for dispensing, placement, and cutting of a ply at specific locations on the mold  224 . 
     The control computer  286  also includes the processor  286   b . Processor  286   b  executes instructions and manipulates data to perform the operations of the control computer  286  such as, for example, a central processing unit (CPU). Although  FIG. 5  illustrates a single processor  286   b  in the control computer  286 , multiple processors  286   b  may be used according to particular needs and reference to the processor  286   b  is meant to include multiple processors  286   b  where applicable. As illustrated, the processor  286   b  includes the programming module  289   a  and the validation module  289   b.    
     The programming module  289   a  can include any software, hardware, firmware, or combination thereof to automatically generate operating parameters  285 . For example, the programming module  289   a  may receive a selection of a composite article and generate operating parameters  285  based on a model for the selected composite article. 
     The validation module  289   b  can include any software, hardware, firmware, or combination thereof configured to evaluate a composite article generated from the dispensing, placement, and cutting program  291  to ensure the generated composite article will meet operating specifications. 
     Network  204  facilitates wireless or wireline communication between the control computer  286  and the material dispensing system  200 . Network  204  may communicate, for example, Internet Protocol (IP) packets, Frame Relay frames, Asynchronous Transfer Mode (ATM) cells, voice, video, data, and other suitable information between network addresses. Network  204  may include one or more local area networks (LANs), radio access networks (RANs), metropolitan area networks (MANs), wide area networks (WANs), all or a portion of the global computer network known as the Internet, and/or any other communication system or systems at one or more locations. As appropriate, the control computer  286  generates requests and/or responses and communicates them to another client, user, server, or other computer systems located in or beyond network  204 . 
     In some embodiments, the material dispensing system  200  is not programmable. 
     The configuration of the rolls  242 ,  252 ,  272  can be selectively adjusted for the desired ply layout (e.g., the desired order and orientation of the ply) for the particular composite article  201  being formed.  FIG. 7A  illustrates an exemplary ply layout for plies dispensed and cut from rolls  242 ,  252 ,  272 . Ply  210  is an exemplary embodiment of a ply of unidirectional tape having a non-bias orientation of about 0° dispensed from the first non-bias ply roll  252 . Ply  211  is an exemplary embodiment of a ply of plain weave fabric having a non-bias orientation of about 0° and about 90° dispensed from the second non-bias ply roll  272 . Ply  212  is an exemplary embodiment of a ply of bias weave fabric having a bias orientation of about 45° and about 135°. 
     Another illustrative embodiment of a desired ply layout for a composite article  201  is shown in  FIG. 7B . The layout in  FIG. 7B  includes two plies of unidirectional fabric  210 ,  217  having a non-bias orientation of about 0° dispensed from the first non-bias ply roll  252 . Two plies of a unidirectional fabric  211 ,  216  having a non-bias orientation of about 90° would be dispensed from a third non-bias ply roll (not shown) disposed on the first application head  230 . Two plies of bias unidirectional fabric  212 ,  215  having a bias orientation of about 45° would be dispensed from a second bias ply roll (not shown) disposed on the first application head  230 . Two plies of bias unidirectional tape  213 ,  214  having a bias orientation of about 135° would be dispensed from a third bias ply roll (not shown) disposed on the first application. In this illustrative embodiment, the first application head  230  includes four rolls having different ply orientations/weaves and includes at least one bias ply roll  242 ; however, it should be appreciated that other embodiments may have fewer or more rolls but include at least one bias ply roll  242 . 
     In an embodiment, the material dispensing system  200  dispenses and cuts tape and/or fabric that are dry fibers that can be wetted with a polymeric matrix either by hand or by injecting the polymeric matrix into a closed mold via an adhesive deliver device  290 , as schematically shown in  FIG. 5 . In an embodiment, the polymeric matrix can be a film, paste, or liquid. In an embodiment, the polymeric matrix can be any suitable resin system, such as a thermoplastic or thermosetting resin. Other exemplary resins can include epoxy, polyimide, polyamide, bismaleimide, polyester, vinyl ester, phenolic, polyetheretherketone (PEEK), polyetherketone (PEK), polyphenylene sulfide (PPS), and the like. 
     In another embodiment, the fibers are impregnated or otherwise situated in a polymeric matrix as a ply of pre-preg on one or more of the rolls  242 ,  252 , and/or  272 . In an embodiment, the pre-preg ply can be an intermediate modulus epoxy resin impregnated carbon fiber fabric on a roll. The intermediate modulus epoxy impregnated carbon fiber fabric can be stiffer than conventional composite fabrics which allows for fewer plies, which reduces the weight and manufacturing cost, while the epoxy resin system can provide tolerance to damage. In an embodiment, a pre-preg ply is dispensed from a roll (e.g., roll  242 ,  252 ,  272 ) and cut via cutter  280 . The step of dispensing can include smoothing the plies to remove any pockets of air using compaction member. In some exemplary embodiment, the compaction member comprises a compaction roller that moves independently from the first application head  230 . 
     Once the fibers are in a polymeric matrix, heat and/or pressure can be used to cure the plies in the polymeric matrix. Once cured, the component may then be machined to its final shape. 
       FIG. 8  is a flowchart illustrating an example method  300  for preparing a composite article using the material dispensing system  200 . Method  300  is described with respect to system  200  of  FIG. 5 . Though, systems  400 ,  500 , and  600  contemplate using or implementing any suitable technique for performing these and other tasks. Method  300  is for illustration purposes only and that the described or similar techniques may be performed at any appropriate time, including concurrently, individually, or in combination. In addition, many of the steps in this flowchart may take place simultaneously and/or in different orders than as shown. Moreover, systems  200 ,  400 ,  500 , and  600  may use methods with additional steps, fewer steps, and/or different steps, so long as the methods remain appropriate. 
     Method  300  includes the following steps: a step  302  of providing a first bias assembly with a first bias roll, a step  304  of providing a first non-bias assembly with a first non-bias roll, a step  306  of positioning the first bias assembly to a dispensing position, a step  308  of dispensing a bias ply from the first bias roll along a bias path on a mold, a step  310  of cutting the bias ply, an optional step  312  of cutting a ply reinforcement strip, a step  316  of positioning the first non-bias assembly to a dispensing position, a step  318  of dispensing a non-bias ply from the first non-bias roll along a non-bias path on a mold, a step  320  of cutting the non-bias ply, and an optional step  322  of cutting a ply reinforcement strip. The bias path and the non-bias path are parallel. In some embodiments, the bias path and non-bias path are substantially identical. 
     In some embodiments, the method  300  includes a step of trimming a ply layup on the mold. 
       FIG. 9  is another example of a material dispensing system  400 . Certain components of the material dispensing system  400  are as described above in connection with the material dispensing system  200 . Those components bear similar reference characters thereto, but with a leading ‘ 4 ’ rather than a leading ‘ 2 ’. The material dispensing system  400  includes a first frame  420 , a second frame  421 , and a third frame  424  (e.g., a plurality of frames). The first frame  420  includes a first application head  430 ; the second frame  421  includes a second application head  431 , and the third frame  424  includes a third application head  434 . Each of the first, second, and third frames  420 ,  421 ,  424  can move along tracks  425 . Tracks  425  include an additional storage tracks  425 a,  425 b to permit the first and second frames to be stored therein when not in operation. The first, second, and third frames  420 ,  421 ,  424  can be operatively coupled to a drive system  427  such that the first, second, and third frames move only in an X direction during dispensing, placement, and cutting processes. The first, second, and third frames  420 ,  421 ,  424  can be driven independently by the drive system  427  (e.g., only the first frame  420 , the second frame  421 , or the third frame  424  at one time). In other embodiments, more than one first, second, and third frames  420 ,  421 ,  424  move along tracks  225  during operation. The material dispensing system  400  can include a network  404  and control computer  486  as described above with respect to system  200  although not shown in  FIG. 9 . 
     The first, second, and third application heads  430 ,  431 ,  434  each include only one biased assembly  440  or non-biased assembly  450 ,  470 . In the illustrative embodiment, the first application head  430  includes a first non-biased assembly  450 ; the second application head  431  includes a biased assembly  440 , and the third application head  434  includes a second non-biased assembly  470 . In an embodiment, the system  400  with a plurality of frames (e.g., frames  420 ,  421 ,  424 ) includes at least one biased assembly  440 . 
     The configuration of the first, second, and third frames  420 ,  421 ,  424  and the respective first, second, and third heads  430 ,  431 ,  434  can be selectively adjusted for the desired ply layout. For example, more or less frames can be included in system  400  to add additional biased and/or non-biased assemblies. In an embodiment, the system  400  with a plurality of frames are configured such that each frame includes only one biased or non-biased assembly. 
       FIG. 10  is another example of a material dispensing system  500 . Certain components of the material dispensing system  500  are as described above in connection with the material dispensing system  200 . Those components bear similar reference characters thereto, but with a leading ‘ 5 ’ rather than a leading ‘ 2 ’.  FIG. 10  illustrates an example of the first frame  220  comprising a robotic arm  520 . The robotic arm  520  may navigate or otherwise move through a manufacturing factory and position itself adjacent to mold  224  and execute the dispensing, placement, and cutting process described herein. In an embodiment, the robotic arm  520  moves along a pair of tracks as shown in  FIG. 5  to perform the dispensing, placement, and cutting process. The material dispensing system  500  includes a network  504  and control computer  586  as described above with respect to system  200  although not shown in  FIG. 10 . 
     In an embodiment, the robotic arm  520  includes, a support member  522 , a mobile platform  523 , a monitoring system  524 , and a first application head  530 . The first application head  530  is mounted on the support member  522 , and the support member  522  is mounted on the mobile platform  523 . The mobile platform  523  is configured to navigate through a manufacturing facility to a position proximate mold  224 , and the support member  522  is configured to move the first application head  530  to predefined position at least proximate and above the mold  224 . During operation, the support member is configured to move during the dispensing, placement, and cutting processes such that the bias path and non-bias paths  246 ,  256  are parallel. In some embodiments, the bias path and the non-bias paths  246 ,  256  are substantially identical. 
     The robotic arm  520  can include any software, hardware, firmware, or a combination thereof configured to move in multiple axes or degrees of freedom. As illustrated, the support member  522  includes links connected by joints that enable rotational motion or translational displacement. In the illustrated implementation, the support member  522  enables motion in  6  axes such as X, Y, Z, pitch, yaw, and roll. Using these multiple axes, the robotic arm  520  can be configured to move the first application head  230  to multiple predefined positions at least proximate and above the mold  224 . 
     The mobile platform  523  can include any software, hardware, firmware, or a combination thereof configured to navigate or otherwise move through a facility (e.g., manufacturing facility). The mobile platform  523  may determine locations using positing data such as radio frequency identifier (RFID) signals, global positioning system (GPS), indoor GPS, photogrammetry, laser tracking, optical CMM, or others. In some instances, the mobile platform  523  is an omni-directional platform allowing for motion in any direction. In some implementations, the mobile platform  523  includes a positioning and safety monitoring system  524  configured to monitor the environment. In some examples, the positioning and safety monitoring system  524  may be configured to scan (e.g., continuously scan) the working envelope to monitor for human movement or obstructions. In some examples, the positioning and safety monitoring system  524  may be configured to provide position feedback to the control computer  286 . 
       FIG. 11  is another example of a material dispensing system  600 . Certain components of the material dispensing system  200  are as described above in connection with the material dispensing system  200 . Those components bear similar reference characters thereto, but with a leading ‘ 6 ’ rather than a leading ‘ 2 ’.  FIG. 11  illustrates an example of the first frame  220  comprising a gantry  620 . The gantry  620  includes a pair of rails  625  supported by stationary support members  622 . The pair of rails  625  support a first application head  630  configured to move in at least an X motion direction. In the embodiment shown, the gantry  620  is stationary and the first application head  630  moves to a position for dispensing plies from at least one first biased assembly  640  onto the mold  626 . In some embodiments, the first application head  630  is configured to move only in an X motion direction. In other embodiments, the first application head  630  is configured to move in X, Y, and Z motions. The material dispensing system  600  includes a network  604  and control computer  686  as described above with respect to system  200  although not shown in  FIG. 11 . 
     In an embodiment, a mold  624  is disposed on a machine base  626 . In the illustrative embodiment, the machine base  626  is disposed between the stationary support members  622 . In other embodiments, the machine base  626  is disposed along the transverse axis Y (e.g., generally perpendicular to the pairs of rails  625 , which are aligned with the longitudinal axis X). 
     In the illustrative embodiment, the first application head  630  includes the first biased assembly  640 , the first non-biased assembly  650 , and, optionally, a second non-biased assembly  670  each being supported by an arm  635 . The arm  635  supports the respective assembly  640 ,  650 ,  670  and provides power thereto to operate the dispenser unit  644 ,  654 ,  674  (not shown). Each assembly  640 ,  650 ,  670  includes the respective ply roll  642 ,  652 ,  672  as described with respect to material dispensing system  200 . In some embodiments, each assembly  640 ,  650 ,  670  can include a respective tension member  638  mounted and powered by the respective arm  635 . In still some illustrative embodiments, each assembly  640 ,  650 ,  670  includes a respective take-up roll  639  supported and powered by a second arm  637 . The second arm  637  is disposed on the first application head  630  and can move therewith. 
     In an illustrative embodiment, the material dispensing system  600  includes at least one ply roll  642 ,  652 ,  672  comprised of one ply of pre-preg  648  and a backing paper  647  adhered thereto. Since the fibers in the pre-preg ply  648  are impregnated in a polymeric matrix and can have a sticky texture, a backing paper  647  is in contact with the ply of pre-preg  648  while on the ply roll  642 . The backing paper  647  needs to be removed from the pre-preg ply  648  prior to placement on the mold  624 . Accordingly, a separator member  636  is supported by the respective arm  635  to separate the backing paper  647  from the pre-preg ply  648  as the ply  648  is dispensed onto the mold  624 . As the backing paper  647  is separated from the pre-preg ply  648 , the backing paper  647  is rotated around the respective tension member  638  and up to the take-up roll  639  and wound therearound. 
     System  600  includes a second movable head  632  that moves in X, Y, Z motions and independently from the first application head  630 . The second movable  632  includes a support arm  633 a to support components thereon. 
     System  600  includes a cutter  680  mounted to the support arm  633 a on the second movable head  632 . In an embodiment, the cutter  680  is a laser cutter mounted on a track  682  supported by a movable arm  684 . The movable arm  684  can be configured to move in X, Y, Z motions for cutting the length and width during or after placement of ply  648 . 
     System  600  also includes a compaction member  633  for pushing the prepreg ply  648  down onto the mold  624 . In an embodiment, the compaction member  633  is a compacting roller disposed on the support arm  633 a. The step of dispensing can include smoothing a ply or several plies to remove any pockets of air using the compaction member  633 . In some exemplary embodiment, the compaction member  633  moves independently from the first application head  230 . In some other embodiments, the compaction member  633  may be disposed on or otherwise associated with the first application head  630 . 
     The material dispensing systems and methods described herein can advantageously provide at least one of the following benefits: plies that cover a larger acreage of a near constant cross-section, as opposed to placing a constantly varying amount of material and sizes of material down around highly tailored features as shown in the prior art  FIG. 2 ; a greatly reduced total ply count and part count as compared to the prior art in  FIG. 2 ; the resulting composite article has sufficient stiffness and torsional support for large area aircraft composites (e.g., wing skin  123 , spar ribs); low cost composite tooling as compared to the tooling required for the pieces and ply buildups used in the conventional tiltrotor wing shown in  FIGS. 1-2 ; a combination of the methods described herein can reduce overall labor costs by more than 50% as compared to the current labor costs for the conventional tiltrotor wing shown in  FIGS. 1-2 ; allows for point-of-use manufacturing for the composite articles; reduces the number of quality defects as compared to the quality defects in the conventional tiltrotor wing in  FIGS. 1 and 2 ; simple de-tooling; reduces costs; reduces cycle time; and increases material throughput. 
     The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. 
     The term “substantially” is defined as largely, but not necessarily wholly, what is specified (and includes what is specified; e.g., substantially  90  degrees includes  90  degrees), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially,” “approximately,” and “about” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 2, and 5 percent. 
     Terms such as “first” and “second” are used only to differentiate features and not to limit the different features to a particular order or to a particular quantity. 
     At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art is within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R I , and an upper, R u , is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R I +k*(R u −R I ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrow terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, the scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.