Layup time for an Automated Fibre Placement process in the framework of a detailed sizing optimisation

Automatic Fibre Placement manufacturing processes have become the aerospace industry standard for the production of large-scale composite components. Besides the challenges linked with the manufacturing of such components, their design process is also complicated leading to the two mainly being treated as different subjects. In this work, the aspect of the layup time required to manufacture the composite component is introduced as an objective function in a detailed sizing optimisation process. The methodology presented is able to identify how the material is going to be laid on the tool, using the sizing information available via a zone-based modelling of the thickness and stiffness properties of the structure. The method is applied to the skin of an aircraft wing and a trade-off between the structural weight and layup time is observed. Results demonstrate that the bi-objective optimisation is a promising tool for reducing the structural mass, while keeping the layup time to acceptable levels by benefiting from a more detailed structural modelling.