Patent ID: 8282758

Claim:
A method of fabricating a composite part using an automated in-line manufacturing system, the method comprising: delivering a supply of one or more resin infused fiber tows to an automated in-line layup system configured to receive the supply of the one or more resin infused fiber tows, the automated layup system comprising at least one guide roller coupled to an extending cylinder, at least one compaction roller disposed downstream from the guide roller and at least one auxiliary roller disposed downstream from the compaction roller, the at least one compaction roller and the at least one auxiliary roller configured to adhere the one or more infused fiber tows to a surface of a substrate, and a positioning and control system to orient the guide roller, the compaction roller and the auxiliary roller about a vertical axis and relative to the surface of the substrate; positioning the supply of the one or more resin infused fiber tows within the automated layup system and between a surface of the compaction roller and a surface of the substrate, defining a feed-through path; laying up a first course of the one or more resin infused fiber tows onto the surface of the substrate, wherein the compaction roller provides a force to adhere the one or more resin infused fiber tows onto the surface of the substrate; positioning the at least one auxiliary roller proximate an end portion of the first course of the one or more resin infused fiber tows that are adhered to the surface of the substrate; retracting the at least one compaction roller from the one or more resin infused fiber tows; extending the cylinder to move the guide roller and generate a buffer amount in the supply of the one or more resin infused fiber tows; cutting the supply of the one or more resin infused fibers between the at least one compaction roller and the at least one auxiliary roller; rotating the automated in-line layup system about a vertical axis to position it for layup of a subsequent course of the supply of one or more resin infused fibers while simultaneously retracting the at least one auxiliary roller to a storage position; positioning the at least one compaction roller onto the supply of one or more resin infused fibers to adhere the supply of the one or more resin infused fibers to a previous adhered course of the one or more resin infused fibers and form an additional course; moving the automated layup system until the buffer amount in the supply of the one or more resin infused fiber tows is taken up and the supply of one or more resin infused fiber tows begins to be adhered to the previously adhered course, wherein a tension on the supply of one or more resin infused fiber tows as provided by the adhered portion of the additional course is greater than the low tension provided by the buffer amount; and repeating the previous steps to define a plurality of courses defining the composite part.