Janicki is expanding its composite manufacturing capabilities with the addition of an automated fiber placement (AFP) machine, opening the door to new parts, processes and opportunities for future growth.
About automated fiber placement
AFP is an advanced manufacturing process that uses automated equipment to precisely place narrow strips of composite fiber pre-impregnated with resin, called tows. By combining accurate fiber placement with controlled heat and compaction, AFP can improve repeatability, part quality and production efficiency, and it gives Janicki another option alongside traditional hand layup.
Janicki’s AFP machine
Although automation increases consistency, the process still depends on skilled technicians. Janicki’s AFP technicians handle material changes, inspections, troubleshooting and machine maintenance, and they watch closely for issues such as twisted tows or resin buildup that could affect part quality. Once a part program is established and saved, the machine can produce highly repeatable layups within its calibrated tolerances.
When paired with an automated rotator, the machine can also manufacture complex enclosed structures, such as ducts and barrels, while minimizing wrinkling.
Janicki’s new machine is a high-rail, gantry-style AFP system from Electroimpact. It is equipped with an eight-lane, 0.25-inch tow head, and it is designed to accommodate a 16-tow head in the future. Its seven-axis configuration and 48-by-16-by-8-foot working envelope allow it to produce both complex geometries and large flat panels.
The machine can place material at up to 3,000 inches per minute, with about 2,000 inches per minute expected during typical operation. It currently provides a maximum deposition width of 2 inches, with the potential to increase with a larger head.
One of the system’s key features is its variable spot-size laser heating. Compared with conventional infrared heating, the laser provides greater control when steering material over complex contours, and it can also support thermoplastic layup.
The AFP system broadens the range of composite manufacturing projects Janicki can take on, from large flat panels to complex contoured parts.
To learn how AFP could support your next program, contact us.