Mikrosam AFP work cell to enhance Qarbon's TPC part development

Mikrosam and Qarbon Aerospace team during FAT Mikrosam’s facility in Macedonia. Source (All Images) | Mikrosam

Mikrosam  (Macedonia, Prilep) has successfully commissioned a robotic automated fiber placement (AFP) work cell at  Qarbon Aerospace Inc.  (Red Oak, Texas, U.S.), which will help Qarbon meet the evolving demands of the aerospace industry for faster rates of manufacturing lightweight, strong parts.

The Libra-series AFP system is specifically designed to elevate Qarbon Aerospace’s R&T capabilities, enabling the production of high-performance thermoplastic composite (TPC) parts with precision and efficiency. The work cell’s key features include:

• Multi-material AFP head . This is capable of processing thermoset, thermoplastic and dry fiber unidirectional (UD) prepreg tapes, ensuring versatility and flexibility in production.
• Advanced heating systems.  Integrated laser heating with multiple pyrometers and fast thermal camera for thermoplastic, and IR heating for thermoset prepregs ensure optimal material consolidation and quality.
• Quality control system (QCS).  Real-time monitoring and reporting of production parameters for traceability and quality assurance aligns with the aerospace industry’s stringent standards.
• MikroPlace software.  The offline programming and simulation tools for seamless part design and production planning enhances efficiency and reduces production time.
• Flexible upgrades.  Options for automated head exchange, tool rotation axis and compatibility with wider tapes (½ inch) for future scalability are available to remain adaptable.
• Automatic head exchange system.  Enables Qarbon to upgrade the AFP work cell in the future with additional AFP heads or end effectors.

The AFP work cell has been tailored to Qarbon Aerospace’s specific requirements. Its scope of supply includes a multi-material AFP head, equipped with laser heating and compaction during the placement of the tows while maintaining constant tow tension to ensure precise material placement. The system’s ability to handle complex geometries, coupled with its closed-loop thermal control, ensures consistent quality and reduces material waste — critical factors for aerospace applications.

Mikrosam’s AFP system.

“We are thrilled to support Qarbon Aerospace with this AFP solution to accommodate different manufacturing processes and materials,” says Vele Samak, vice president at Mikrosam. “Combined with Qarbon’s know-how in producing thermoplastic parts, we believe this addition will speed up parts development and open new markets.”

The installation of Mikrosam’s AFP work cell at Qarbon marks a major milestone in the company’s effort to advance its composites manufacturing capabilities, particularly for thermoplastic technologies like induction welding and  Helios ice protection.

The AFP system supports active R&T projects while positioning Qarbon to transition advanced TPC processes into future production programs. “This system is a strategic investment in our future,” adds John Hannappel, research and technology manager at Qarbon Aerospace. “It not only advances our ability to develop and validate thermoplastic technologies, but also strengthens our position to support future defense and commercial programs with scalable, high-performance solutions.”

Qarbon Aerospace has also partnered with  Toray Advanced Composites  (Morgan Hill, Calif., U.S.), leveraging its high-quality composite materials — and Toray Cetex thermoplastic prepregs and UD tapes in particular — to further enhance the performance and reliability of the aerospace components it produces. The Cetex brand features optimal resin distribution and highly consistent fiber alignment, making the material well suited for large structural components while eliminating processing steps and minimizing overall costs. It is offered in a wide range of fiber-resin combinations and meets aerospace OEM’s strict specifications.