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  • Automated Kitting
  • Automating the production of advanced composites

Automated Kitting of composites plies

Kitting, sorting or sequencing of the composites plies is a complex process. The operators have to manually keep track of the many plies that are cut from multiple materials, and collate and order them to make the kits. This requires companies to commit significant human resources to this critical step of the production process, or to limit nesting of the plies to simplify the job, but accept significant waste of raw material. Airborne’s automated kitting solutions enable you to reduce both labour and material waste, while ensuring that the process is easy to manage and error free.

What are the benefits of automating the sorting and ordering process of composites ply kits?

Automation ensures that quality products are produced efficiently and with minimum waste. By automating the process of sorting and sequencing the plies into kits ready for layup, Airborne’s Automated Kitting solution ensures that error-free, composites plies kits are delivered to the lamination stations.
  • Reduced production cost

  • Automated programming: quick and easy setup

  • Enables higher nesting mix: less waste

  • Full digital control: flexible, no sorting mistakes, 100% data trace mistakes

Download free brochure on Automated Kitting

Further advantages are:

  • Reduce manual labour

  • Redeploy skilled workers

  • Reduce engineering effort

  • Improve material utilisation

Further advantages are:

  • Reduce waste material disposal cost

  • Reduce cost of quality control

  • Reduce footprint

  • Capture new business opportunities

How does automated sequencing of composite plies work?

Airborne has developed a plug-and-play, Automated Kitting solution for composite plies. Plies are loaded on a conveyor, or automatically fed from the ply cutter (a digital cutting system). The machine then picks the plies from the conveyor belt cutter and sorts them into groups on trays, drawers or cabinets in a buffer station. The pregroupped plies are then automatically sequenced in the order required for layup. Airborne’s proprietary buffer system design ensures fast operation and a small footprint. 

Performance

Airborne’s standalone and integrated Automated Kitting solutions can kit up to 220 plies per hour and up to 1200 plies per production run. The exact performance of the automated sorting machine depends on the number of kits kitted per production run and the average number of plies per tray.

The kitting algorithm is selected automatically depending on the production requirements to deliver the best performance. A kitting rate of 150 or 220 plies per hour is achieved in most cases. Performance tailoring to specific requirements may be possible through hardware and/or software customisation.

standalone solution

Airborne’s standalone Automated Kitting solution enhances automated cutting by automating the sequencing process. By working independently from the cloth cutter, it is an ideal fit for an up and running facility with one or more cutters that is looking to increase its productivity and material utilization.

integrated solution

Airborne’s integrated Automated Kitting solution delivers all the advantages of the standalone solution, with the additional benefit of further reducing the manual labor content associated with the cutting and kitting process through integration of the cutter. As an end-to-end material roll to ply kits process it is the ultimate sorting solution.

Want to dive in deeper? 

Download technical paper

Download the study by Jens de Kanter on Automated composite ply kitting and preforming

In this paper we take a look at the challenges for the industry, the traditional kitting process and the opportunities for and advantages of automating the kitting process. And, as a next step, we discuss how the automated kitting process could be extended to include preforming as well.

More automated solutions

Automated Honeycomb Potting

Our Honeycomb Potting solution enables easy manufacturing of locally reinforced honeycomb sandwich panels, while reducing work preparation, material waste and the cost of quality.

Automated Laminating

Our Laminating solution makes the layup of tailored thermoset prepreg preforms effortless, by combining tape laying, cutting, and pick & place in a single cell.

Automated Preforming

Our Preforming solution is the solution to manufacture tailored blanks or preforms, 100% netshape, and for all composite materials: thermoset prepreg, dry fibre or thermoplastic composites.

Contact

 

For more information about our products and services, please contact:

Mattia Di Francesco – Business Development Manager Airborne

Tel +31(0)61 3846576
m.difrancesco@airborne.com
Contact

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  • Home
  • Products & services
    • Industrialisation Partner
    • Automated Systems
      • System Integration
      • Automated Kitting
      • Automated Honeycomb Potting
      • Automated Laminating
      • Automated Preforming
    • Digital Solutions
    • Design & Manufacturing
  • Industries
    • Aeronautics
    • Automotive
    • Space
    • Renewables
    • Marine
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  • Downloads
    • Brochures & Specifications
    • White papers & Trend reports
    • Technical papers & Presentations
    • Webinars
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