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Over the years, ever-increasing design complexity and variability needs required of next-generation composite structures have led to advancements in automated fiber placement (AFP) technology. Tow steering, geared to place precise courses (or tows) of prepreg along commanded curvilinear paths, is one capability that has greatly matured. However, AFP steers fibers via tow bending, which results in tow buckling, and consequently wrinkles and defects.

Rapid Tow Shearing (RTS) emerged as a solution to these limitations. It relies on in-plane shearing of tows to steer fibers, eliminating concern of buckled tows and wrinkles. Commercialized by iCOMAT (Bristol, U.K.), a University of Bristol spin-off, in 2019, RTS brings significant productivity gains from aerospace to automotive to space. A prime example of these gains can be observed on the curved beam seen above, which was produced via iCOMAT’s lay-flat and form approach — a manufacturing method where fibers are sheared in 2D to enable defect-free forming in 3D. This approach is only possible with RTS says iCOMAT, which enables shearing fibers around corners, thereby reducing forming defects. Additionally, it is 20 times faster than direct AFP and reduces component weight in this example by 17%.