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MAG's new GEMINI Composite Processing System

MAG's new GEMINI Composite Processing System offers head docking, switches from fiber placement to tape laying in minutes

MAG IAS addresses the aerospace industry's drive for economy and flexibility in composites processing by introducing the new GEMINI Composite Processing System – the first system capable of switching in a matter of minutes from automated fiber placement to automated tape laying. "The new GEMINI system saves several million dollars in equipment, infrastructure and labor cost traditionally needed for two separate systems, making it ideal for aerospace tier suppliers who require cost economy and flexible capabilities," said Robert Harper, Director of Sales for MAG's composite products. The first GEMINI system has already been purchased by Alliant Techsystems (NYSE: ATK). It will be installed at ATK's Iuka, Mississippi facility, bringing to eight the total number of MAG fiber placement systems installed at ATK plants. The order includes MAG's modular ACES® software (Advanced Composites Environment Suite), the industry's fastest and most powerful programming and simulation system for both tape laying and fiber placement.

"For a fraction of the cost of a full tape laying system, aerospace composite part suppliers can now add tape laying capability on a fiber placement machine or vice versa, saving millions on machinery, plant infrastructure, labor and training otherwise needed for two machines," said Randy Kappesser, Vice President MAG Composites. "The system makes it possible for fabricators to consider combining composite tape and fiber in the same part, and it certainly can improve the cost structure for the industry by maximizing equipment utilization and facilitating use of lower cost tape to a greater extent. Even the modular vertical gantry design is engineered with flexibility in mind. It can be configured for multiple work zones or extremely long parts, while providing excellent workzone access for head changing and tool loading."

The new GEMINI system utilizes MAG's industry-leading VIPER® automated fiber placement (AFP) head, and CHARGER™ or the Forest Liné ATLAS automated tape laying (ATL) heads. "The ability to dock an ATLAS head, which utilizes pre-cut roll dispensing from MAG Forest Line's Access system, is another productivity advantage of the GEMINI Docking Head system," said Kappesser. Head docking cradles outside the workzone allow efficient offline setup or maintenance of heads while the machine can continue to produce parts. Head changing requires about two minutes. The gantry design of the system accommodates both fixed floor-mounted or rotation type tooling in Outer Mold Line (OML) or Inner Mold Line (IML) configurations. The gantry is modular and available in various widths, as well as with X-axis rails on top of the floor or in-floor. It can be ordered in any length required, in addition to carrying multiple gantries. A new wireless control pendant gives the operator greater freedom and convenience in working with the system.

The AFP heads handle tow widths of 3.2, 6.4 and 12.7 mm (0.125, 0.25, 0.5 in), producing fiber band widths up to 203.3 mm (8 in). They provide independent control over feed, clamp, cut and re-start for up to 16 individual tows of composite prepreg slit tape, allowing automated "on-the-fly" adjustment of the fiber band width, controlled placement of fibers around changing contours, and precise configuration of openings. The system allows wrinkle-free, near-net-shape lay-up of enclosed and deeply contoured structures and concave/convex surfaces. It is ideal for precision production of fuselage sections, panels, cowls, ducts and nozzle cones for commercial, military and space vehicles, including parts that make use of lightweight honeycomb core materials.

MAG's CHARGER tape laying head deposits carbon/epoxy tape at speeds up to 100 m/min (4000 ipm) while achieving aerospace grade placement accuracies on complex contours. It applies 75, 150 or 300 mm (3, 6 or 12 in) carbon/epoxy tape with any orientation and number of plies, ensuring consistent quality, part shape, thickness and strength. The head allows fast, simple side loading of tape rolls up to 300 mm (12") wide and 650 mm (25.6") diameter. Common hardware permits lay-up of 150 mm (6") and 300 mm (12") wide tape with minimal changeover time. The advanced head design also features integrated ultrasonic laminate cutting, cutter depth-setting assistance, and dockable inkjet marking for maximum system flexibility and performance. An infrared heating system provides faster response and greater precision than air heating, and maximizes lay-down rates with a wider variety of materials.

The Forest Liné ATLAS tape head has the ability to dispense pre-cut rolls of material that were made on the Forest Liné Access system. Along with the pre-cut roll of tape, the ATLAS head can also simultaneously carry bulk rolls of material 150 or 300 mm (6 or 12 in) wide, allowing a part to be laid using pre-cut rolls of material and material from the bulk rolls of tape.

MAG pioneered automated composites processing for building aerostructures, and its systems are widely used in major worldwide aircraft programs, with over 130 installations globally, nearly 40% of them in Europe and Asia. Recent additions to MAG's global composite processing installed base include a VIPER 1200 installed in Russia and sale of its first tape layer to China.

Press release issued by Fives Machining Systems, Inc. on January 25, 2012


 Contact details from our directory:
Fives Machining Systems, Inc. Composite Manufacturing Supplies, Boring Equipment, Lathes, Machining Systems, Cutting Equipment, Cutting Tools, Composite Tape Lay-down, Grinding, Laminating Equipment, Gantries, Drilling Equipment, Routing, Milling, Numeric Control Equipment, Materials Handling Equipment, Systems Integration
Orbital ATK - Aerospace Structures Rocket Motor Ignition Systems, Exhaust Systems, Engine Nozzles, Weapons Countermeasures, Engine Fan Casings, Wings, Springs, Aircraft Structural Components, Nacelles, Fuselage Sections, Engine Inlets, Shafts & Shaft Assemblies, Subcontracted Composite Parts


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