In 2009 Magestic Systems partnered with Nikon Metrology to develop a robust system for testing the thickness of cured laminate composite parts.  Magestic Systems developed TruPLY™ Compensation to translate data collected by Nikon Metrology's Laser Radar into workable information that streamlines the manufacturing process for composite parts.

At final inspection, TruPLY™ Compensation interprets a point cloud of “as-built” data that defines the thickness of the composite part off the tooled surface and compares it against the “as-designed” engineering model to determine thickness and structural integrity.  TruPLY™ Compensation detects zones on a composite part, such as a wing skin, that are out of engineering tolerance for thickness and calculates the shape and quantity of compensation plies required to build the part back into tolerance.  TruNEST™ then automatically generates the NC code to cut the new compensation plies, as well as the laser projection files to place them accurately on the composite part.

			TruPLYTM Compensation Features Optimize material usage by minimizing need for sacrificial plies Avoid capital acquisition of large milling machines and required tooling fixtures Reduce associated facility costs and floor space requirements Eliminate sacrificial plies on wing skins to reduce weight and increase fuel efficiency Introduce sustainable/green production process for composite part manufacturing Less scrap material being thrown away Final products are built to operate more fuel efficiently The facility footprint is reduced requiring less energy
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TPC Adds Value to the Composite Part Manufacturing Sector in Many Ways:

The value created by this process is in immediate material savings, reduced aircraft weight and increased production throughput. Traditionally, to prevent a composite part from being too thin in critical areas excess or sacrificial plies were added to the part during the original lay-up process. The part was cured, and then machined to within structural and engineering requirements.  The CLC process eliminates the need for sacrificial plies, which in turn saves composite material and reduces the weight of the aircraft.  In addition, The CLC process prevents manufacturers from having to purchase large milling machines, absorb facility costs and floor space requirements.

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