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Composite parts are difficult to produce, especially the control of the part thickness. This paper/presentation is in two parts, and describes an innovative process using integrated metrology for composite part manufacturing of a generic wing flap. This first paper describes the composite assembly process from a metrology focus and how an integrated Laser Radar system is used to measure actual thickness build-up compared to theoretical CAD/CAM nominal. The second paper is on the automation capability of making the part. A robot is used to apply the composite ply's/tows. To analyze the machines capability and tune performance a high speed photogrammetry system is used. It is also used for automated placement of honeycombed structures within the part build, where guided assembly can be automated in future.

Composite parts are difficult to produce, especially the control of the part thickness. This paper/presentation is in two parts, and describes an innovative process using integrated metrology for composite part manufacturing of a generic wing flap. The first paper describes the composite assembly process from a metrology focus and how an integrated Laser Radar system is used to measure actual thickness build-up compared to theoretical CAD/CAM nominal. This second paper is on the automation capability of making the part. A robot is used to apply the composite ply's/tows. To analyze the machines capability and tune performance a high speed photogrammetry system is used. It is also used for automated placement of honeycombed structures within the part build, where guided assembly can be automated in future.