3DEXPERIENCE Laser Projection Technology for Composite Manufacturing

Hand Layup is a widely used composite manufacturing process. This method involves lot of manual efforts. Obviously any manual process involves challenges related with quality consistency. So as to ensure repeatability of manufacturing process, laser projection is widely used in composite industry for locating plies on tooling surface.

For locating plies with respect to tooling surface, ply boundaries are projected on tooling surface by using laser projection camera. Depending on size of the ply and shape, no of cameras for projection are decided. Same factors decides the location of camera with respect to the tooling surface. Usually the location of camera’s and no of camera is defined by trial and error method and needs experienced guess work. This leads to loss of production time, additional set up cost and challenges for repeatability.

This entire process of location of laser projection camera and number of cameras for laser projection can be digitally simulated. Digital simulation of laser projection set up helps to reduce set up time on the shop floor and helps to maintain repeatability of set up at different manufacturing sites.

3DEXPERIENCE provides very efficient tool for digital simulation of laser projection set. It allow composite manufacturers define number of laser projection cameras needed for accurate positioning of plies on tooling surface. It allows them define accurate location of cameras with respect to tooling surface for accurate positioning of plies on tooling surface. While defining location and number of cameras 3DEXPERIENCE allows manufacturers to consider manufacturing and space constraints on shop floor.  

3DEXPERIENCE Laser Projection functionality allows manufacturer to project additional details includes name of ply, seed curve, seed point, material details, and orientation of plies in addition to ply boundaries. This helps shop floor operator to do final check before ply is placed on tooling surface.3DEXPERIENCE laser projection is very accurate tool. It considers location ply within stack while projecting ply boundaries. This helps to define location of plies above core accurately. The accuracy of projection can be controlled by defining the sag value or element size. Laser Projection tool allow to project cut pieces of plies, darts as well making sure all required geometry for ply positioning is available on tooling surface.

3DEXPERIENCE Laser Projection tool allows to export laser projection data in all format needed by laser projection camera. It support laser projection cameras by Virtek, LPT, LAP, and Assembly Guidance. The output from 3DEXPERIENCE laser projection tool is usually in .ply or .cal format.3DEXPERIENCE laser projection tool allows to read .ply files which helps to recreate manufacturing environment digitally. Another key advantage of 3DEXPERIENCE integrated tool is no data loss while creating laser projection data by reading composite design data.

3DEXPERIENCE laser projection tool allows manufacturers to reduce set up time on shop floor, making manufacturing process efficient and repeatable.


Kedar Upadhye

Enthusiast of Digital Composite Technology

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30th June


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