Patent ID: 7867352

Claim:
A method of applying a course on a layup mold, the method comprising: determining a ply boundary that defines a ply area on the layup mold; applying a tape of composite material on the ply area at an oblique angle relative to the ply boundary, the tape having a centerline and a leading edge being cut at an angle of between about 80° to about 100° relative to the centerline, the leading edge and the ply boundary essentially converging; generating a trailing edge, the trailing edge being cut at an angle of between about 80° to about 100° relative to the centerline, the trailing edge and the ply boundary essentially converging; and staggering the leading and trailing edges of the tape in relation to the leading and trailing edges of tape of at least one other ply such that, within a transition zone, the intersections of the centerline of the tape with the leading and trailing edges thereof are non-coincident with the intersections of the centerline of the tape of the at least one other ply with the leading and trailing edges thereof, the leading and trailing edges of the tape of the at least one other ply being cut at an angle of between about 80° to about 100° relative to the tape centerline thereof.